Multifunctional Electrode Structure with Layered Active Materials
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Solution Overview
Problem
Current electrode manufacturing methods for energy storage devices like batteries and supercapacitors limit the ability to tailor the micro or meso structure of electrodes, leading to inefficient lithium ion diffusion and reduced power density, especially in thicker electrodes, resulting in wasted costly materials and suboptimal performance.
Innovation Solution
The development of a multifunctional electrode structure comprising discrete layers with different electrochemically active materials strategically placed to maximize performance, using a layer-by-layer processing technique such as spraying, allowing for varying thickness and composition to optimize energy and power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If slurry casting is used to manufacture electrodes with uniform microstructure, then manufacturing stability and automation are improved, but the ability to tailor through-thickness microstructure is restricted and lithium ion diffusion efficiency deteriorates
Solution Approach 1:
The electrode is divided into multiple discrete layers (first layer with first electrochemically active material, second layer with second electrochemically active material) instead of using a uniform monolithic structure. This segmentation allows each layer to have different compositions and properties optimized for specific functions, resolving the contradiction between manufacturing simplicity and microstructure tailoring capability.
Solution Approach 2:
Different regions of the electrode (different layers) are given different qualities and compositions. The first layer contains materials optimized for certain electrochemical properties while the second layer contains materials with different electrochemical properties, allowing local optimization of lithium ion diffusion and electron transport in specific regions of the electrode.
2Quantity of substance
If thicker electrodes are used to increase energy density, then energy storage capacity is improved, but lithium ion diffusion efficiency and power density deteriorate
Solution Approach 1:
The electrode structure uses layers with different local qualities - one layer optimized for high surface area and lithium ion diffusion (improving power density) and another layer optimized for high material loading and energy storage (improving energy density). This allows the electrode to achieve both high energy density and high power density simultaneously by having different regions perform different functions.
Solution Approach 2:
The electrode is constructed as a composite structure with at least two different electrochemically active materials in separate layers. This composite approach allows combining materials with complementary properties - one material providing high surface area for fast kinetics and another providing high capacity for energy storage, thereby resolving the trade-off between energy density and power density.
3Ease of manufacture
If uniform composition is used throughout the electrode, then manufacturing simplicity is maintained, but material utilization efficiency deteriorates due to non-uniform lithium ion diffusion
Solution Approach 1:
Instead of using a uniform composition throughout, the electrode is segmented into layers with different compositions. The first layer contains a first electrochemically active material and the second layer contains a second electrochemically active material, allowing each layer to be optimized for specific functions such as lithium ion diffusion, electron transport, or energy storage, thereby improving material utilization efficiency.
Solution Approach 2:
Different layers are given different local qualities and material compositions based on their specific functions. This allows materials to be placed in the most favorable positions for their operation, maximizing their utilization efficiency rather than having uniform composition that cannot be optimized for specific regions.
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
This approach enhances the electrical storage performance by optimizing material utilization and placement, improving both energy and power densities, and reducing material costs by focusing expensive materials where they are most effective.
Implementation Method 1
delivering the first and second suspension to a spraying means, operating the spraying means for a period of time to spray the first and second suspension on to a substrate
Data Source
AI summary
An electrode structure comprises a conductive substrate or current collector and a first layer comprising a first electrochemically active material, the first active material being characterized by one or more first electrochemical properties. A second layer comprises a second electrochemically active material, the second active material being characterized by one or more second electrochemical properties, at least one of which is different from said one or more first electrochemical properties. The first and second layers are provided at predefined locations within the electrode structure based on the respective first and second electrochemical properties of the first and second electrochemically active materials to maximise the performance of each of the first and second layers. A method of fabricating such an electrode structure is also provided.