Porous Structured Composite Materials for Conductive Active Deposition

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Solution Overview

Problem

Existing composite materials lack a structured framework that efficiently integrates active and conductive components, particularly in small pores with high aspect ratios, limiting their performance in applications such as battery electrodes and electronic devices.

Innovation Solution

A method of producing structured composite materials (SCMs) by depositing an electrically conductive material on porous media particles and then coating them with an active material, using controlled environments and energy processes to coalesce the particles, forming a continuous matrix that enhances conductivity and activity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional composite materials are used without structured framework, then manufacturing process is simpler, but electrical conductivity and active material deposition efficiency are poor

Engineering Contradiction:

Improveelectrical conductivityVSAvoidstructured framework complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The composite material is segmented into distinct functional components: porous media particles providing structural framework, electrically conductive material forming continuous pathways, and active material deposited within pores. This segmentation allows each component to optimize its function while maintaining overall performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates a multi-phase composite material system combining porous media (structural support), electrically conductive material (charge transport), and active material (functional response). The hierarchical composite structure resolves the contradiction by integrating multiple materials with complementary properties to achieve both high conductivity and complex functionality.

Inventive Principle:

Principle #40Composite materials

2Area of stationary object

If high surface area porous media is used, then active material deposition area increases, but particle coalescence difficulty increases

Engineering Contradiction:

Improvesurface areaVSAvoidparticle coalescence ease

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The electrically conductive material acts as an intermediary substance that facilitates particle coalescence. It deposits on porous media particle surfaces, creating bonding bridges between particles while preserving the high surface area structure. This intermediary enables manufacturing ease without sacrificing surface area for active material deposition.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The use of porous media with controlled pore structures allows high surface area to be maintained while the porous structure itself facilitates particle interaction and coalescence. The pores provide pathways for conductive material penetration and bonding, resolving the contradiction between surface area and coalescence ease.

Inventive Principle:

Principle #31Porous materials

3Productivity

If small pores with high aspect ratios are used, then active material deposition efficiency improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improveactive material deposition efficiencyVSAvoidpore structure precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The porous media structure with small high aspect ratio pores is prepared in advance before active material deposition. This preliminary structuring optimizes the substrate for efficient active material uptake while the subsequent deposition process follows established protocols, reducing the precision demands during the actual manufacturing step.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention optimizes pore size and aspect ratio parameters of the porous media to achieve high active material deposition efficiency. By carefully selecting and controlling these geometric parameters during porous media synthesis, the system achieves high productivity while managing manufacturing precision requirements through parameter optimization rather than extreme precision.

Inventive Principle:

Principle #35Parameter changes

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 resulting SCMs exhibit improved electrical conductivity, high surface area, and efficient deposition of active materials within small pores, leading to enhanced performance in energy storage, electronic, and structural applications.

Implementation Method 1

depositing an electrically conductive material on surfaces or within pores of the plurality of porous media particles

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 2

converting the process input material into separated components by adding energy to the process input material

Methodology Applied

Scientific EffectEnergy conversion:

Implementation Method 3

coalesce the plurality of porous media particles together to form the structured composite material

Methodology Applied

Scientific EffectCoalescence:

Data Source

PatentUS12580176B2Structured composite materials

Publication Date: 2026.03.17 LYTEN INC

AI summary

A method of producing a structured composite material is described. A porous media is provided, an electrically conductive material is deposited on surfaces or within pores of the plurality of porous media particles, and an active material is deposited on the surfaces or within the pores of the plurality of porous media particles coated with the electrically conductive material to coalesce the plurality of porous media particles together and form the structured composite material.