Sintered Electrode Structures for High Energy Batteries
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Solution Overview
Problem
Current lithium rechargeable batteries have low volumetric and gravimetric utilization of active materials, poor electron and ion transport, and thermal conductivity, limiting their energy and power density, especially in high-power applications.
Innovation Solution
The development of co-fired electrode-separator structures and sintered electrodes with high density, which eliminate the need for conductive additives and binders, allowing for thicker electrodes with improved thermal and electronic conductivity, and reduced inactive material mass fraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If particulate-based electrodes are used with polymer binders and conductive additives, then electrode processing is improved, but volumetric utilization of active material decreases to less than 50%
Solution Approach 1:
The patent removes polymer binders and conductive additives from the electrode structure, extracting the harmful elements that occupy volume without contributing to energy storage. This extraction enables >50% volumetric utilization of active material while maintaining electrode integrity through alternative design approaches.
Solution Approach 2:
The patent employs porous electrode structures where the porosity provides both mechanical integrity and ion transport pathways, eliminating the need for polymer binders. The porous architecture allows high active material density while maintaining processing capability through the inherent structural properties of the porous material.
2Reliability
If carbon additives are added to improve electronic conductivity, then electrode conductivity is improved, but volume occupied by low specific gravity carbon additives increases
Solution Approach 1:
The patent extracts carbon additives from the electrode composition entirely, achieving electronic conductivity through alternative mechanisms such as conductive metal foils as current collectors or intrinsically conductive active materials, thereby eliminating the volume occupied by low-specific-gravity carbon particles.
Solution Approach 2:
The patent uses composite structures combining conductive metal current collectors with active materials, creating a composite electrode where the conductive component provides both structural support and electrical conductivity, replacing the need for separate carbon additive phase.
3Reliability
If thin electrode structure is used to achieve complete utilization of active material, then ion transport is improved, but mass fraction of non-storage materials increases
Solution Approach 1:
The patent uses porous electrode structures that maintain short ion transport paths while accommodating high active material loading. The porous architecture provides three-dimensional ion transport networks that reduce dependence on thin electrode geometry, enabling thick electrodes with high active material content and reduced non-storage material fraction.
Solution Approach 2:
The patent transitions from two-dimensional planar electrode structures to three-dimensional porous networks, creating multiple ion transport pathways through the electrode thickness. This dimensional change allows thick electrodes to achieve complete active material utilization through enhanced ion diffusion networks.
4Ease of manufacture
If particulate-based electrodes are used, then electrode fabrication is simplified, but thermal conductivity decreases due to point contact heat transport
Solution Approach 1:
The patent employs composite electrode structures incorporating thermally conductive components such as metal foils or thermally conductive fillers within the electrode matrix, creating a composite material that provides both structural integrity and enhanced thermal conductivity pathways for heat dissipation.
Solution Approach 2:
The patent replaces point-contact heat transport between particles with continuous thermal conduction pathways through integrated metal current collectors or conductive networks, substituting the discontinuous thermal transport mechanism with a continuous conduction system.
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 results in lithium rechargeable batteries with specific energy exceeding 300 Wh/kg and specific power over 600 W/kg, achieving unprecedented mass and volume efficiency while maintaining high electrochemical utilization and safety.
Implementation Method 1
In high power batteries, the thermal conductivity of electrodes should also be high to prevent excessive heating during cycling that causes degradation of energy and power and limits the life of the battery. Particulate-based electrodes have poor thermal conductivity since heat must be transported from particle to particle through narrow point contacts.
Implementation Method 2
Co-fired electrode-separator structures for rechargeable batteries... sintered electrodes with high density
Data Source
AI summary
Subassemblies for use in an electrochemical device are provided, as are processes for preparing the subassemblies and electrochemical cells incorporating the subassemblies. In some embodiments, the subassemblies include (a) a first electrode and (b) a separator or a first current collector or both. The first electrode is bonded to the separator or the first current collector or both. In some embodiments, the subassemblies further include a second electrode and a second current collector. In some embodiments, the electrodes or separators are sintered. Bipolar cells are also provided, including a plurality of stacked electrochemical cells that are joined in series. The positive electrode and the negative electrode of each stack include a sintered electrode.