Porous Binder Scaffold for High Energy Density Cathodes
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Solution Overview
Problem
Existing lithium batteries face challenges in achieving high energy density, stable performance, and long lifespan due to uneven distribution of cathode materials and lithium ion flow characteristics, leading to issues like dendrite formation and reduced stability as the cathode active material layer thickness increases.
Innovation Solution
The electrochemical device incorporates a cathode with a porous binder scaffold and evenly dispersed cathode active material particles, supported by a conductive material, to form a thick film type cathode with a uniform distribution of materials, enhancing energy density and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the cathode active material layer thickness is increased to achieve high energy density, then the energy density increases, but the uniformity of lithium ion flow and charge/discharge characteristics deteriorates
Solution Approach 1:
The patent employs a porous binder scaffold structure in the cathode active material layer that provides three-dimensional lithium ion transport pathways. This porous architecture enables uniform lithium ion distribution throughout the thick cathode layer (50-2000 μm) while maintaining high energy density, as the pores facilitate efficient ion diffusion even in thick films.
Solution Approach 2:
The patent applies local quality by creating a non-uniform internal structure within the cathode layer through the porous binder scaffold, where the scaffold density and pore distribution are optimized in different regions to ensure uniform lithium ion flow throughout the entire thick cathode structure, addressing the specific needs of each region within the thick film.
2Use of energy by moving object
If the cathode active material layer thickness is increased to achieve high energy density, then the energy density increases, but the lifespan characteristics deteriorate
Solution Approach 1:
The porous binder scaffold structure provides stable three-dimensional support that maintains structural integrity during repeated charge/discharge cycles in thick cathode layers. This porous architecture prevents material degradation and maintains uniform lithium ion flow, thereby extending battery lifespan while enabling high energy density through increased cathode thickness.
Solution Approach 2:
The patent creates a composite structure combining the porous binder scaffold with cathode active material particles, where the scaffold provides mechanical stability and ion transport pathways while the active material provides electrochemical functionality. This composite architecture enables thick cathode films to maintain both high energy density and long cycle life.
3Use of energy by moving object
If the cathode active material layer thickness is increased to achieve high energy density, then the energy density increases, but polarization phenomenon occurs
Solution Approach 1:
The porous binder scaffold creates extensive three-dimensional lithium ion transport pathways that reduce ion transport resistance throughout the thick cathode layer. This porous structure eliminates polarization phenomena by ensuring uniform and efficient lithium ion distribution, even in cathodes with thicknesses of 50-2000 μm, while maintaining high energy density.
4Use of energy by moving object
If the cathode active material layer thickness is increased to achieve high energy density, then the energy density increases, but dendrite formation on lithium metal anode occurs
Solution Approach 1:
The porous binder scaffold in the thick cathode layer ensures uniform lithium ion extraction and distribution during charge cycles, preventing localized concentration gradients that would otherwise drive dendrite formation on the lithium metal anode. This uniform ion flow through the porous structure enables high energy density without the harmful dendrite effect.
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 an energy density of 400 Wh/kg or more, with excellent lifespan characteristics and stability, suppressing polarization and ensuring uniform charge/discharge characteristics.
Implementation Method 1
the porous binder scaffold further comprises a conductive material
Implementation Method 2
a cathode active material layer formed on the cathode current collector, wherein the cathode active material layer includes a porous binder scaffold and cathode active material particles
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
The present disclosure relates to an electrochemical device that can simultaneously satisfy a high energy density of 400 Wh/kg or more, excellent lifespan characteristics, and stability. The electrochemical device according to the present disclosure includes a cathode; an anode including an anode current collector, or the anode current collector and lithium metal; and an electrolyte; wherein the cathode includes a cathode current collector; and a cathode active material layer formed on the cathode current collector, and including a porous binder scaffold and cathode active material particles.