Reticulated Electrode Structure for Battery Surface Area

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Solution Overview

Problem

Existing electrochemical batteries face challenges in increasing the reacting surface area of electrodes without compromising structural strength, as traditional methods like sculpting or using woven screens are limited by mechanical stress and erosion, and reticulated metal structures are costly and difficult to uniformly coat with conductive materials.

Innovation Solution

A method involving a reticulated substrate coated with a conductive material, followed by ultrasonic treatment to promote adhesion and deep penetration of the coating, and subsequent electroplating to ensure uniform coverage and increased surface area, using either reticulated polymer foam or ceramic materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If the surface area of the plates is increased by sculpting or using thin sections, then the reacting surface area is improved, but the structural strength deteriorates due to mechanical stress and erosion

Engineering Contradiction:

Improvereacting surface areaVSAvoidstructural strength

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The patent applies porous reticulated substrate materials (such as reticulated vitreous carbon or metal foams) that provide high surface area through their porous structure while maintaining structural integrity. The interconnected porous network allows electrolyte penetration throughout the volume, providing reacting surface area without requiring thin sections that would compromise strength.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite structures combining the reticulated substrate with conductive material coatings and active material layers. This multi-layer composite approach allows the substrate to provide structural strength while the porous structure and coatings provide increased reacting surface area through their textured interfaces.

Inventive Principle:

Principle #40Composite materials

2Productivity

If reticulated metal structures are used to increase surface area, then the capacity and efficiency are improved, but the manufacturing cost increases and uniform coating becomes difficult

Engineering Contradiction:

Improvebattery capacity and efficiencyVSAvoidmanufacturing cost and coating uniformity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces difficult mechanical coating processes (such as vacuum plating or plasma deposition) with electroplating methods. The electroplating process uses electrical current to deposit conductive material uniformly throughout the porous structure, penetrating deep into the core where mechanical methods fail, achieving uniform coating at lower cost.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the deposition method from physical vapor deposition to electrochemical deposition. By using electroplating with controlled electrical parameters (current density, plating time, electrolyte composition), uniform coating throughout the porous structure is achieved, penetrating deep into the core where vacuum plating and plasma deposition only deposit thick coats on the bearing surface.

Inventive Principle:

Principle #35Parameter changes

3Area of stationary object

If holes are made through the plate to increase surface area, then the reacting surface area is improved, but the structural integrity deteriorates and the battery reliability decreases

Engineering Contradiction:

Improvereacting surface areaVSAvoidbattery reliability

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The patent uses a porous reticulated substrate structure where holes are distributed throughout the material in a controlled, interconnected network. This porous structure provides extensive reacting surface area while the reticulated framework maintains structural integrity, preventing collapse or contact between neighboring plates that would occur with discrete holes.

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 approach enhances the capacity and efficiency of electrochemical batteries by increasing the reacting surface area, reducing weight and unusable metals, while allowing for economical mass production and improved structural integrity.

Implementation Method 1

electroplating the reticulated substrate coated with the conductive material with a desired metal material

Methodology Applied

Scientific EffectElectroplating: Electroplating

Implementation Method 2

applying ultrasonic wave to break down a surface tension at the boundary layer of the reticulated substrate to promote adhesion of the conductive material

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS10862100B2Reticulated electrode structure and method of making the same

Publication Date: 2020.12.08 KATHLEEN M SNAPER TRUSTEE OF THE SNAPER FAMILY TRUST DATED MAY 19 2022

AI summary

A method of forming an electrode in an electrochemical battery comprises: coating a reticulated substrate with a conductive material; curing the reticulated substrate coated with the conductive material; and electroplating the reticulated substrate coated with the conductive material with a desired metal material.