Self-Standing Electrode Tab Embedding via Aerosol Co-Deposition
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Solution Overview
Problem
Self-standing electrodes without current collectors pose a challenge in attaching battery tabs, as traditional methods rely on current collectors for electrical conductivity.
Innovation Solution
A method involving aerosolizing or fluidizing electrode active materials and co-depositing them with carbon nanotubes onto a porous surface, embedding a battery tab attachment structure within the composite to form a three-dimensional network, enabling tab attachment without binders or collectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional current collector foils are used in electrodes, then electrical conductivity and tab attachment are achieved, but the electrode structure becomes more complex and additional materials (binders, current collectors) are required
Solution Approach 1:
The patent extracts and eliminates the current collector foil and binder from the electrode structure, creating a self-standing electrode where the active material forms its own structural framework. This removes unnecessary components while maintaining tab attachment capability through direct embedding in the active material matrix.
Solution Approach 2:
The active material serves multiple functions simultaneously: it provides the electrochemical function, structural support, and tab attachment substrate. The conductive additive network provides both electrical conductivity and mechanical binding, eliminating the need for separate current collector and binder components.
2Quantity of substance
If current collectors are removed to simplify electrode structure, then material quantity is reduced, but the method of tab attachment becomes more difficult
Solution Approach 1:
The tab attachment structure is embedded within the active material matrix during the electrode formation process itself, before final assembly. This preliminary integration ensures proper positioning and electrical connection without requiring separate attachment steps after electrode fabrication.
Solution Approach 2:
The tab attachment structure is nested within the active material composite, with conductive additives and active material surrounding and embedding the tab connection point. This nested arrangement provides both mechanical support and electrical pathways through the composite structure.
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 allows for effective tab attachment and electrical conductivity in self-standing electrodes, maintaining structural integrity and facilitating current transport without the need for current collectors.
Implementation Method 1
aerosolizing or fluidizing an electrode active material to produce an aerosolized or fluidized electrode active material
Implementation Method 2
aerosolizing or fluidizing an electrode active material to produce an aerosolized or fluidized electrode active material
Implementation Method 3
co-depositing the aerosolized or fluidized electrode active material and carbon nanotubes onto a first porous surface
Data Source
AI summary
The present disclosure is directed to methods and embedding battery tab attachment structures within composites of electrode active materials and carbon nanotubes, which lack binder and lack collector foils, and the resulting self-standing electrodes. Such methods and the resulting self-standing electrodes may facilitate the use of such composites in battery and power applications.