Prelithiated Hybrid Electrode Structure for High-Energy Storage

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing energy storage devices face limitations in achieving high energy and power densities while maintaining cycle efficiency and being cost-effective.

Innovation Solution

The development of a hybrid energy storage device with a first electrode comprising electrochemically active material and porous carbon particles, and a second electrode comprising lithium-intercalating carbon particles and elemental lithium metal, which can be pre-lithiated to enhance performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional electrodes without pre-lithiation are used, then manufacturing simplicity is maintained, but energy density and cycle efficiency are limited

Engineering Contradiction:

Improveenergy densityVSAvoidelectrode structure complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent applies pre-lithiation to the electrodes before final assembly, incorporating lithium metal particles into the electrode structure in advance. This preliminary action ensures lithium availability for subsequent cycling, improving energy density and cycle efficiency without requiring complex in-situ lithium generation mechanisms during operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite electrode structures combining conventional active materials with lithium metal particles and conductive carbon materials. This composite approach creates a multi-functional electrode that provides both energy storage capacity and structural stability, resolving the contradiction between improved energy density and maintained manufacturing simplicity.

Inventive Principle:

Principle #40Composite materials

2Power

If high amounts of lithium metal are added to increase energy density, then power delivery improves, but electrode structural stability deteriorates

Engineering Contradiction:

Improvepower deliveryVSAvoidelectrode structural stability

Core Design Contradiction:

PowerVSStability of the object's composition

Solution Approach 1:

The patent distributes lithium metal particles locally throughout the electrode structure rather than concentrating them in one area. This local distribution, combined with intercalating lithium into carbon materials at specific sites, provides power delivery enhancement while maintaining overall electrode structural stability through localized functional zones.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs porous carbon materials that can intercalate lithium ions while maintaining structural integrity. The porous structure allows lithium insertion/extraction without compromising the carbon framework, enabling power delivery improvement while preserving electrode structural stability during cycling.

Inventive Principle:

Principle #31Porous materials

3Reliability

If pre-doping processes are implemented during fabrication, then cycle efficiency improves, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecycle efficiencyVSAvoidfabrication simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the pre-lithiation step with the standard electrode fabrication process by incorporating lithium metal particles during the mixing and coating stages. This integration eliminates the need for separate pre-doping equipment and processes, improving cycle efficiency while maintaining manufacturing simplicity and cost-effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses the electrode fabrication process itself to provide the pre-lithiation function, where lithium metal particles are incorporated during normal manufacturing operations. This self-service approach allows the standard fabrication line to perform both electrode formation and pre-lithiation, avoiding additional manufacturing complexity and cost.

Inventive Principle:

Principle #25Self-service

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 configuration enables the hybrid energy storage device to achieve high energy density and power delivery, with improved cycle efficiency and reduced costs, by utilizing elemental lithium metal in a pre-lithiated state within the electrode structure.

Implementation Method 1

a second electrode comprising lithium-intercalating carbon particles and elemental lithium metal

Methodology Applied

Scientific EffectIntercalation: Absorption (physical)

Data Source

PatentUS20250174709A1Prelithiated hybridized energy storage device

Publication Date: 2025.05.29 TESLA INC

AI summary

An energy storage device can include a first electrode, a second electrode and a separator between the first electrode and the second electrode wherein the first electrode includes an electrochemically active material and a porous carbon material, and the second electrode includes elemental lithium metal and carbon particles. A method for fabricating an energy storage device can include forming a first electrode and a second electrode, and inserting a separator between the first electrode and the second electrode, where forming the first electrode includes combining an electrochemically active material and a porous carbon material, and forming the second electrode includes combining elemental lithium metal and a plurality of carbon particles.