Monolithic Porous Open-Cell Structures for Energy Storage
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Solution Overview
Problem
Current methods for preparing monolithic porous open-cell structures for energy storage devices and filtration systems are limited in terms of efficiency and scalability, as they often result in structures with inconsistent pore sizes and reduced ion and electron transfer lengths, affecting the performance of batteries and capacitors.
Innovation Solution
A process involving the formation of a microparticulate mass, consolidation into a template, infiltration with a framework material, and subsequent removal to create a monolithic porous open-cell structure with a void volume fraction of at least 25%, allowing for improved ion and electron transfer and enhanced performance in energy storage applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional template methods (colloidal self-assembly, interference lithography) are used to fabricate porous structures, then pore size control is achieved, but manufacturing complexity and scalability are limited
Solution Approach 1:
The patent employs a porous template made of porous beads (e.g., porous glass beads) with controlled pore sizes. The template itself is a porous material that allows infiltration of conductive material while maintaining structural integrity. This approach simplifies fabrication compared to complex lithography methods while achieving consistent pore sizes through selection of beads with specific pore dimensions.
Solution Approach 2:
The porous template acts as an intermediary structure that mediates between the fabrication process and the final conductive porous product. The template is infiltrated with conductive material (metal, carbon, conductive polymer) and then removed, leaving a replica structure. This intermediary approach enables simple fabrication while achieving precise pore size control through template selection.
2Productivity
If highly porous structures are created for energy storage applications, then ion and electron transfer efficiency is improved, but structural integrity and mechanical strength are reduced
Solution Approach 1:
The final structure is a composite of conductive material (metal, carbon, or conductive polymer) forming a porous network. This composite structure provides both the high porosity needed for ion/electron transfer and the mechanical strength through the conductive material framework. The conductive material reinforces the porous structure while maintaining high void volume fraction (at least 25%).
Solution Approach 2:
The structure exhibits local quality variations with conductive material distributed throughout the porous framework. The walls of the pores are composed of conductive material providing strength and electrical conductivity, while the interior pores remain open for ion transport. This local differentiation allows simultaneous optimization of mechanical strength and transport efficiency.
3Power
If void volume fraction is increased to enhance power performance, then electrical conductivity and ion transfer are improved, but structural stability is compromised
Solution Approach 1:
The patent utilizes porous conductive materials (porous metal, porous carbon, or porous conductive polymer) that inherently maintain structural stability despite high porosity. These materials have interconnected pore networks with thin walls that provide both high surface area for electrochemical reactions and sufficient mechanical strength. The void volume fraction is maintained at least at 25% while preserving structural integrity through the porous material's inherent properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process enables the creation of structures with optimized pore sizes and interconnectivity, leading to enhanced power performance and flexibility in energy storage devices, such as batteries, by increasing the void volume fraction and improving electrical conductivity.
Implementation Method 1
consolidating comprises compressing or sintering the mass of microparticles
Implementation Method 2
infiltrating the template with a framework material that coats the non-contacting surface regions of the microparticles
Data Source
AI summary
Process for the fabrication and manufacture of highly porous open-cell structures using templates that are formed by mechanical pressing, injection molding, sintering, or any combination thereof. The processing scheme includes coating, filling or depositing a material on, or inside the porous template. The highly porous structure results after the selective removal of the template and can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.