Self-Standing Electrode Composite for Fast-Charge Conductivity

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Solution Overview

Problem

Self-standing electrodes for Li-ion batteries lack sufficient electrical conductivity due to the absence of a current collector, limiting their use in fast-charging applications.

Innovation Solution

Incorporating conductive metal, such as copper or aluminum, into the electrode active material or carbon nanotubes to enhance electrical conductivity, using methods like aerosolization and deposition on a porous substrate to form a composite electrode structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If self-standing electrodes are formed without current collector and binder to increase specific energy density, then specific energy density is improved (40% higher), but electrical conductivity deteriorates (low relative to Cu/Al current collector foils)

Engineering Contradiction:

Improvespecific energy densityVSAvoidelectrical conductivity

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent applies composite materials by combining carbon nanotubes with conductive metal particles (copper, aluminum, or aluminum oxide) to create a self-standing electrode that achieves both high energy density and sufficient electrical conductivity. The composite structure allows the electrode to function without traditional Cu/Al current collector foils while maintaining the necessary conductive pathways for electron transport.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conductive material is added to enhance electrical conductivity, then electrical conductivity is improved, but device complexity increases (additional materials and processing steps)

Engineering Contradiction:

Improveelectrical conductivityVSAvoidelectrode structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into a single integrated structure. The conductive metal particles are incorporated directly into the carbon nanotube matrix during the aerosol deposition process, creating a unified composite electrode structure that simultaneously provides mechanical support, electrical conductivity, and active material hosting, eliminating the need for separate current collector and binder layers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent controls the morphology and distribution parameters of the conductive metal particles during aerosolization and deposition. By adjusting particle size, concentration, and deposition conditions, the patent optimizes the conductive network formation within the composite electrode, achieving sufficient electrical conductivity through parameter optimization rather than structural complexity.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If conventional aerosolization methods are used to deposit electrode materials, then deposition is achieved, but homogeneous distribution of conductive material and nanotubes is difficult

Engineering Contradiction:

Improvedeposition efficiencyVSAvoidhomogeneous distribution

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent segments the deposition process into separate aerosol streams - one containing carbon nanotubes and another containing conductive metal particles. These segmented streams are then combined and co-deposited onto the substrate, allowing each component to be independently controlled and optimized before merging, which facilitates more homogeneous distribution compared to mixing all materials in a single aerosol stream.

Inventive Principle:

Principle #1Segmentation

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 electrodes exhibit improved electrical conductivity and energy density, making them suitable for fast-charging applications while maintaining a higher energy density compared to conventional electrodes.

Implementation Method 1

aerosolizing or fluidizing electrode active material and conductive material

Methodology Applied

Scientific EffectAerosolization: Aerosol

Implementation Method 2

depositing nanotubes, the aerosolized or fluidized electrode active material, and the aerosolized or fluidized conductive material on a porous substrate

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 3

applying a pressure differential across the porous material to draw the at least one suspension or dispersion from the element, through the porous material, and to the container

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS20240290938A1Self-standing electrodes and methods and apparatus for making the same

Publication Date: 2024.08.29 HONDA MOTOR CO LTD

AI summary

Aspects of the present disclosure generally relate to battery technology, and more specifically relate to self-standing electrodes and to methods and apparatus for making the same. In an embodiment, a self-standing electrode is provided. The self-standing electrode includes nanotubes, electrode active material, and conductive material. In another embodiment, a method of forming a self-standing electrode is provided. The method includes aerosolizing or fluidizing electrode active material and conductive material. The method further includes depositing nanotubes, the aerosolized or fluidized electrode active material, and the aerosolized or fluidized conductive material on a porous substrate to form a self-standing electrode, the self-standing electrode comprising the nanotubes, the electrode active material, and the conductive material.