Separator-Based Electrodes That Eliminate Metal Collectors
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Solution Overview
Problem
Energy storage devices face issues with metallic collectors that increase weight, reduce energy density, and are expensive, fragile, and cause manufacturing challenges due to their thinness.
Innovation Solution
Hybridizing inks with graphene fibers to use the separator as a collector, eliminating the need for metal collectors by forming electrodes directly on the separator, which includes conductive additives, binders, and solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic collectors are used to provide conductivity for electrodes, then electrical conductivity is ensured, but weight increases and energy density decreases
Solution Approach 1:
The patent removes the metallic collector component entirely from the energy storage device structure. Instead of using separate metal collectors to provide conductivity, the invention integrates conductivity directly into the electrode material through conductive additives dispersed in the electrode matrix, thereby eliminating the weight penalty of metallic collectors while maintaining electrical conductivity
Solution Approach 2:
The patent merges the functions of the electrode and collector into a single integrated component. The electrode itself becomes conductive through the incorporation of conductive additives (such as carbon black, carbon nanotubes, or graphene), eliminating the need for a separate metallic collector layer and reducing overall device weight
2Reliability
If metallic collectors are used to ensure proper electrode function, then electrical conductivity is maintained, but manufacturing costs increase
Solution Approach 1:
The patent replaces expensive metallic collectors with cost-effective conductive additives that can be incorporated directly into the electrode slurry at low concentrations. These additives (such as carbon-based materials) are significantly cheaper than metals like aluminum or copper, reducing material costs while maintaining the necessary electrical conductivity for electrode function
Solution Approach 2:
The patent creates a composite electrode material by dispersing conductive additives within the electrode matrix. This composite approach allows the use of inexpensive conductive fillers (carbon black, carbon nanotubes, graphene) combined with standard electrode materials, achieving the required conductivity without relying on expensive metallic collectors
3Weight of moving object
If collector thickness is reduced to decrease weight and cost, then weight and price are reduced, but manufacturing reliability decreases due to fragility
Solution Approach 1:
The patent eliminates the thin metallic collector layer entirely, removing the source of manufacturing fragility. By integrating conductivity into the electrode material itself through conductive additives, the invention avoids the problem of thin, fragile metal collectors that are prone to breaking during manufacturing and assembly processes
4Stability of the object's composition
If metallic collectors are used to provide structural support for electrodes, then electrode stability is ensured, but device complexity and material sourcing difficulty increase
Solution Approach 1:
The patent removes the metallic collector component that creates material sourcing challenges and geopolitical dependencies. By using conductive additives that can be incorporated into the electrode slurry, the invention eliminates the need for separate metal collector procurement, reducing supply chain complexity and material sourcing difficulties
Solution Approach 2:
The patent changes the fundamental parameter of how conductivity is achieved in the electrode system. Instead of relying on metallic collectors with specific material properties, the invention modifies the electrode material composition by adding conductive fillers, allowing for greater flexibility in material selection and reducing dependence on specific metal sources
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 reduces total mass, improves energy density, lowers costs, minimizes oxidation issues, and simplifies manufacturing by using versatile materials like cellulose or polymers, enhancing device stability and environmental friendliness.
Implementation Method 1
hybridizing the inks with graphene fibers, which provide the necessary conductivity to the electrode without the use of a metal collector
Data Source
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AI summary
The device for storing and/or converting energy (1) comprises one or more spacers (2) defining two sides; and electrodes (3) in contact with one or both sides of the spacer (2), each electrode (3) comprising an ink including at least one conductive additive. The method comprises the following steps: preparing an ink, the ink comprising at least one conductive additive; and forming electrodes (3) with the ink, the electrodes (3) being in contact with one or both sides of one or more spacers (2). It allows the separator itself to act as a collector at the same time, providing a solution to the problem of oxidation of metal collectors, among others.