Porous Battery Electrode Layout for Uniform Electrolyte Wetting

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Solution Overview

Problem

Rechargeable batteries face issues with incomplete electrolyte wetting during manufacturing, leading to non-uniform electrode reactions, localized lithium precipitation, and reduced productivity, especially as electrode sizes increase.

Innovation Solution

The electrode design includes varying hole densities in the active material layer, with denser holes in areas with poor impregnation and sparser holes in well-impregnated areas to enhance uniform electrolyte impregnation, improving ion mobility and reducing lithium precipitation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the size of electrode plates increases to increase battery capacity, then the battery capacity increases, but the electrolyte wetting becomes incomplete and non-uniform

Engineering Contradiction:

Improvebattery capacityVSAvoidelectrolyte wetting uniformity

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The active material layer is designed with non-uniform porosity distribution, where the porosity varies in different regions of the layer. This local quality variation allows the electrolyte to penetrate more effectively into thicker or less accessible regions of larger electrode plates, ensuring uniform wetting across the entire electrode while maintaining high battery capacity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The active material layer incorporates a porous structure with controlled porosity (0.1 to 0.5) and varying pore size distribution. This porous architecture provides channels for electrolyte penetration throughout the electrode, particularly improving wetting in larger electrode plates where complete penetration is more difficult to achieve

Inventive Principle:

Principle #31Porous materials

2Quantity of substance

If the size of electrode plates increases to increase battery capacity, then the battery capacity increases, but the impregnation time increases

Engineering Contradiction:

Improvebattery capacityVSAvoidimpregnation time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

By varying the porosity locally within the active material layer, the patent creates regions with different pore densities and sizes that are optimized for rapid electrolyte uptake. This allows larger electrode plates to achieve complete impregnation faster, as the electrolyte can penetrate through the porous network more efficiently without requiring extended impregnation time

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the physical parameters of the active material layer, specifically the porosity and pore size distribution. By optimizing these parameters within specific ranges (porosity 0.1 to 0.5, pore size 1 to 10 micrometers), the electrolyte impregnation speed is enhanced, allowing larger electrodes to be fully impregnated in shorter times

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the electrolyte wetting is incomplete, then the manufacturing process is faster, but the battery performance degrades and safety risks increase

Engineering Contradiction:

Improvemanufacturing speedVSAvoidbattery performance and safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The porous structure with optimized porosity and pore size is built into the active material layer during manufacturing, creating pre-formed channels that facilitate rapid and uniform electrolyte penetration. This preliminary structural preparation ensures that even with reduced impregnation time, complete and uniform electrolyte wetting is achieved, maintaining battery performance and safety

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The porous active material layer acts as a built-in electrolyte distribution network. The controlled porosity (0.1 to 0.5) and pore size (1 to 10 micrometers) ensure that electrolyte can rapidly penetrate and uniformly distribute throughout the electrode, achieving both fast manufacturing cycles and reliable battery performance without compromising safety

Inventive Principle:

Principle #31Porous materials

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 design shortens impregnation time, reduces non-impregnated areas, and enhances fast charging capabilities while preventing lithium precipitation, thus improving battery performance and lifespan.

Implementation Method 1

the active material layer... includes a plurality of holes... the second density portion is arranged at both sides (e.g., opposite sides) of the first density portion

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS20250336981A1Electrode for rechargeable battery and electrode assembly including the same

Publication Date: 2025.10.30 SAMSUNG SDI CO LTD

AI summary

An electrode for a rechargeable battery according to one or more embodiments of the present disclosure includes: a substrate; and an active material layer that is formed on the substrate, includes a plurality of holes, and includes a first density portion and a second density portion. The first density portion has a higher density than that of the second density portion, the second density portion has a lower density than that of the first density portion, and the second density portion is disposed at both sides (e.g., opposite sides) of the first density portion.