Solid Electrode Manufacturing via Porous Particle Impregnation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery technologies, particularly lithium battery cells, rely on liquid electrolytes, which limit the performance of solid electrodes in terms of energy density, capacitance, and high-current capability due to incomplete ion penetration and mechanical stability issues.
Innovation Solution
A method for manufacturing solid electrodes using porous active material particles impregnated with an ion-conducting liquid, followed by the addition of a solid electrolyte, allowing for deeper ion penetration and improved ionic contact, enhancing energy density and high-current capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid electrolytes are used in battery cells, then ease of manufacture is improved, but energy density and high-current capability deteriorate due to incomplete ion penetration
Solution Approach 1:
The patent changes the physical state parameter of the electrolyte from liquid to solid, and uses a two-stage impregnation process with different electrolyte forms (liquid followed by solid) to optimize both manufacturability and energy density. This parameter transformation resolves the contradiction by enabling complete pore penetration while maintaining processing feasibility.
Solution Approach 2:
The patent applies preliminary impregnation with liquid electrolyte before final solid electrolyte addition. This preliminary action ensures that porous structures are pre-filled and stabilized, allowing subsequent solid electrolyte to complete the penetration and achieve maximum energy density without compromising manufacturability.
2Ease of operation
If liquid electrolytes are used in battery cells, then ease of operation is improved, but high-current capability deteriorates due to mechanical stability issues
Solution Approach 1:
The patent creates a composite electrolyte system combining liquid and solid electrolyte components. The liquid component provides ionic conductivity and ease of operation, while the solid component provides mechanical stability and enables high-current capability. This composite approach resolves the contradiction by integrating complementary properties of both material types.
Solution Approach 2:
The patent applies different electrolyte types to different locations within the electrode structure. Liquid electrolyte is used in regions requiring flexibility and ionic transport, while solid electrolyte is used in regions requiring mechanical stability. This local differentiation enables both ease of operation and high-current capability simultaneously.
3Area of stationary object
If porous active material particles are used, then surface area is improved, but mechanical stability deteriorates
Solution Approach 1:
The patent utilizes porous active material particles with controlled pore structures to maximize surface area for electrochemical reactions. The porous structure is then impregnated with electrolyte to provide mechanical support and maintain structural integrity. This approach resolves the contradiction by decoupling surface area enhancement from mechanical stability through the electrolyte filling process.
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 method significantly improves the intrinsic properties of solid electrodes, including energy density and high-current capability, by ensuring complete ion penetration and mechanical stability, particularly in highly porous materials like sulfur-based active materials.
Implementation Method 1
the open pores of the porous active material particles may be infiltrated and/or essentially completely filled up using the ion-conducting, in particular lithium-ion-conducting liquid
Implementation Method 2
a solid electrode may be formed from the impregnated active material particles by adding at least one solid electrolyte
Data Source
AI summary
A method for manufacturing a solid electrode. To more strongly utilize the intrinsic properties of a porous active material with respect to capacitance and therefore energy density and also rate and high-current capability, in the method, porous active material particles are impregnated using an ion-conducting liquid which contains monomers and/or oligomers in particular and a solid electrode is formed from the impregnated active material particles by adding at least one solid electrolyte. In addition, the invention relates to such solid electrodes and all-solid-state cells.