3D Porous Battery Anode Structure for Thick Electrode Utilization
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Solution Overview
Problem
Conventional Li-ion battery anodes face challenges in achieving high areal capacity and charge rate while maintaining energy density and stability, particularly with thicker designs, due to limitations in ion and electron transport and active material utilization.
Innovation Solution
A battery cell with an anode comprising interconnected filaments in a predetermined structural arrangement, forming a porous structure with intra-structure pores, utilizing a carbon-based active material, which allows for increased active material loading and improved ion access, enabling higher areal capacity and charge rate without compromising energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of the anode is increased to increase energy density, then the active material loading increases, but the ion transport distance increases and charge transfer kinetics deteriorate
Solution Approach 1:
The anode is segmented into multiple thin layers stacked on top of each other, with each layer containing interconnected filaments. This segmentation reduces the ion transport distance within each layer while maintaining high overall active material loading through the stacked configuration.
Solution Approach 2:
The invention transitions from a conventional planar electrode structure to a three-dimensional stacked layer configuration. This dimensional change allows ions to access active material through multiple pathways and reduces the effective transport distance while increasing the overall capacity.
2Device complexity
If conventional block geometry electrodes are used with binders, then the electrode structure is simple, but the pore structure is inappropriate and ion transport is limited
Solution Approach 1:
The anode employs a porous structure formed by interconnected filaments with deliberate void spaces between them. This porous architecture facilitates efficient ion transport while maintaining structural integrity, replacing the conventional dense block geometry with binder mixtures.
Solution Approach 2:
The invention extracts and removes the conventional binder material from the electrode structure, replacing it with a self-supporting filament network. This elimination of binders improves ion transport efficiency while maintaining structural coherence through the filament interconnections.
3Quantity of substance
If graphite is used as anode material for high capacity, then Li+ intercalation capacity increases, but volume change during intercalation/de-intercalation occurs
Solution Approach 1:
The filament structure provides localized structural support at each intersection point, allowing the graphite material to undergo volume changes during Li+ intercalation without compromising the overall electrode integrity. The interconnected network distributes mechanical stress locally.
Solution Approach 2:
The thin filament structure acts as a flexible framework that can accommodate volume changes of the graphite material during charging and discharging cycles. The filament network deformable structure absorbs expansion and contraction without breaking electrical connectivity.
4Quantity of substance
If thick electrode design is used to increase energy density, then active material loading increases, but a significant portion of the electrode remains unutilized
Solution Approach 1:
Dividing the thick electrode into multiple thin stacked layers ensures that all active material is accessible to ions. Each thin layer is fully utilized, and the stacking configuration maintains high overall loading while preventing the center regions from becoming inaccessible.
Solution Approach 2:
The stacked three-dimensional configuration provides multiple access pathways for ions to reach active material throughout the electrode volume. This dimensional approach ensures uniform utilization of all active material regardless of thickness.
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 solution achieves a significant increase in areal capacity by up to 50% and maintains high charge/discharge reversibility, even with thicker anodes, by enhancing ion and electron transport and active material accessibility, thus improving battery performance and reducing costs.
Implementation Method 1
ion transport in the electrode is limited
Implementation Method 2
electron transport
Data Source
AI summary
The invention relates to a battery cell comprising a three-dimensional porous anode and a method of manufacturing of the battery cell with said anode. A build material comprising a carbon based active material is used, the carbon based active material configured to participate in a battery electrode reaction. Furthermore, interconnected filaments of a build material are deposited in a predetermined arrangement in a plurality of stacked layers, wherein the filaments of the consecutive layers are connected to one another to obtain a porous anode structure with intra-structure pores formed between filaments.