Single-Layer Reference Electrode With Porous Conductive Coating
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Solution Overview
Problem
Existing reference electrodes for electrochemical analysis in batteries are expensive and require complex manufacturing processes due to their non-porous, permeable gold film construction, which limits their widespread adoption.
Innovation Solution
A single-layered reference electrode assembly is developed, comprising a porous separator with a continuous electroactive material layer and electrically conductive material, fabricated using a one-step process such as spin-coating, ink-jet printing, or spray-coating, which reduces production complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a non-porous permeable gold film construction is used for reference electrodes, then measurement precision and reliability are improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent applies porous materials by replacing the traditional non-porous gold film with a porous conductive coating layer. This porous structure allows for better electrolyte penetration and ion transport while maintaining electrical conductivity, thereby simplifying the manufacturing process and reducing costs while preserving measurement precision for electrode potential monitoring.
Solution Approach 2:
The patent employs composite materials by combining porous conductive materials with electroactive materials in a single integrated layer. This composite structure eliminates the need for separate non-porous gold film and electroactive material layers, reducing manufacturing complexity and cost while maintaining the necessary electrical and electrochemical properties for accurate potential monitoring.
2Measurement precision
If a non-porous permeable gold film construction is used for reference electrodes, then measurement precision and reliability are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent applies porous materials by replacing the traditional non-porous gold film with a porous conductive coating layer. This porous structure allows for better electrolyte penetration and ion transport while maintaining electrical conductivity, thereby simplifying the manufacturing process and reducing costs while preserving measurement precision for electrode potential monitoring.
Solution Approach 2:
The patent adopts cheaper alternative materials for the conductive coating and electroactive material layers, replacing expensive non-porous gold film constructions. These cost-effective porous materials achieve the necessary performance for reference electrode functionality at significantly lower manufacturing costs, making the technology economically viable for widespread adoption.
3Ease of operation
If a multi-layered construction with conductive coating and electroactive material layer is used, then electrode potential monitoring capability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent applies merging by combining the conductive coating layer and electroactive material layer into a single integrated porous layer. This unified structure performs both electrical conduction and electrochemical reactions simultaneously, eliminating the need for separate fabrication steps and reducing overall device complexity while maintaining full electrochemical analysis capability.
Solution Approach 2:
The patent employs universality by designing a single porous layer that simultaneously provides electrical conductivity, ion transport pathways, and electrochemical activity. This multi-functional design eliminates the need for separate specialized layers, reducing the number of fabrication steps and simplifying the overall device structure while preserving comprehensive electrochemical monitoring capabilities.
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 single-layered reference electrode assembly enables efficient monitoring of electrode potentials during cycling with stable performance and reduced manufacturing costs, making it suitable for various applications including automotive and industrial uses.
Implementation Method 1
the electroactive material layer may include an electroactive material and an electrically conductive material... enable monitoring of individual potentials during cycling
Implementation Method 2
The electroactive material layer may include an electroactive material and an electrically conductive material... continuous electroactive material layer disposed on a surface of the porous separator
Implementation Method 3
a porous separator and a continuous electroactive material layer disposed on a surface of the porous separator... suitable for conducting lithium ions between the electrodes
Data Source
AI summary
A reference electrode assembly includes a porous separator and a continuous electroactive material layer disposed on a surface of the porous separator. The electroactive material layer includes between about 20 wt. % and about 80 wt. % of an electroactive material and between about 20 wt. % and about 80 wt. % of an electrically conductive material. A loading density of the electroactive material is greater than or equal to about 0.01 mAh/cm2 to less than or equal to about 0.1 mAh/cm2. The electroactive material can be selected from the group consisting of: LiFePO4 (LFP), lithium-aluminum alloys, lithium-tin alloys, and combinations thereof; and the electrically conductive material can be selected from the group consisting of: carbon black, carbon nanotubes, graphite, metal nano-micro particles, and combinations thereof. The continuous electroactive material layer is disposed on the surface of the separator using a one-step process selected from spin-coating electrode casting, ink-jet printing, and spray-coating.