Porous Metal Substrate Anode for High-Capacity Lithium-Ion Batteries
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Solution Overview
Problem
Current electrochemical battery electrodes, particularly in lithium-ion batteries, face limitations in specific capacity due to the inability of graphite to intercalate more than one lithium per six carbon atoms, leading to dendrite formation and other issues such as low density, incompatibility with anode coating technologies, and hysteresis in voltage profiles, while hard carbon offers higher capacity but with drawbacks like low density and larger irreversible capacity.
Innovation Solution
A self-supporting porous metal substrate acts as both an electrode and current collector, with tailored pore size and distribution similar to hard carbon, enabling ion intercalation and release, and is made through methods like sintering nanoparticles or dealloying processes, potentially using copper or other metals to enhance electrical conductivity and capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If graphite is used as anode material, then interfacial stability and low operating potential are achieved, but specific capacity is limited to 372 Ah/kg due to inability to intercalate more lithium
Solution Approach 1:
The patent employs a porous metal substrate structure where the porous architecture provides multiple intercalation sites for lithium ions throughout the three-dimensional structure. This allows significantly more lithium to be stored compared to conventional graphite, achieving specific capacities exceeding 372 Ah/kg while maintaining structural stability through the porous framework.
Solution Approach 2:
The patent creates a composite structure by coating the porous metal substrate with carbon material. This composite approach combines the high capacity advantage of hard carbon with the electrical conductivity and structural stability of metal substrates, resolving the contradiction between capacity and stability.
2Quantity of substance
If hard carbon is used to increase capacity to around 450 Ah/kg, then specific capacity is improved, but low density and larger irreversible capacity are exhibited
Solution Approach 1:
The porous metal substrate provides a controlled pore structure that facilitates uniform lithium ion distribution and access. This reduces concentration gradients and minimizes irreversible capacity loss during initial cycles, while maintaining the high specific capacity advantage of hard carbon-like structures.
Solution Approach 2:
The patent modifies key parameters including pore size distribution, surface area, and material composition to optimize lithium ion transport and reduce irreversible capacity. By controlling these parameters, the system achieves high reversible capacity while minimizing energy loss.
3Quantity of substance
If hard carbon is used to achieve higher capacity, then specific capacity increases, but density remains low
Solution Approach 1:
The patent combines hard carbon coating with a metal substrate (such as copper or aluminum) to create a composite anode. This composite structure leverages the high density and structural integrity of metal while incorporating the high lithium intercalation capacity of hard carbon, thereby achieving both high specific capacity and improved density.
Solution Approach 2:
The porous metal substrate provides a high surface area to volume ratio that increases the effective density of lithium storage sites. The three-dimensional porous network allows more lithium to be accommodated within a given volume, effectively increasing the volumetric and gravimetric energy density.
4Quantity of substance
If hard carbon is used to increase capacity, then specific capacity improves, but incompatibility with current anode coating technologies occurs
Solution Approach 1:
The porous metal substrate serves multiple functions simultaneously: it acts as the current collector, provides structural support, enables lithium ion transport through its porous structure, and serves as a substrate for carbon coating. This multi-functionality simplifies the manufacturing process and improves compatibility with existing coating technologies.
Solution Approach 2:
The porous structure of the metal substrate provides excellent adhesion properties and surface area for carbon coating deposition. This facilitates the application of carbon layers using conventional coating techniques, resolving the incompatibility issue while maintaining the high capacity benefits of hard carbon.
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 porous metal substrate achieves a specific capacity greater than graphite, comparable to or exceeding hard carbon, while reducing dendrite formation risks, and functions effectively as both an electrode and current collector, improving battery performance without the need for a separate current collector.
Implementation Method 1
the pores of the metal substrate may be tailored to have the same diameter or other characteristics of a hard carbon material... capable of ion intercalation and release
Implementation Method 2
the component includes a self-supporting porous metal substrate capable of acting as both an electrode and a current collector... For example, many electrochemical batteries comprise a metal current collector bound to each electrode which gathers electrons, and moves them to an external circuit
Implementation Method 3
made through methods like sintering nanoparticles
Data Source
AI summary
A component for use in an electrochemical battery, wherein the component includes a self-supporting porous metal substrate capable of acting as both an electrode and a current collector in an electrochemical battery. The present disclosure is also directed to methods of making the components of the present disclosure and electrochemical batteries including at least one component according to the present disclosure.