Solid-State 3D Battery Assembly with Bicontinuous Carbon Anode
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Solution Overview
Problem
Conventional battery systems, such as lithium ion batteries, fail to meet the size and power demands of miniaturized electronic devices, and traditional battery architectures are poorly transferrable to small-scale devices due to limitations in energy and power density, with thin film batteries facing challenges in maintaining power capability due to poor ionic conductivity of solid electrode materials.
Innovation Solution
A solid-state three-dimensional battery assembly featuring a bicontinuous monolithic carbon anode with an ordered three-dimensionally continuous network nanostructure, a pinhole-free solid electrolyte layer, and a solid cathode, where the electrolyte layer is sandwiched between the anode and cathode, allowing for increased areal energy density without compromising power capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thin film batteries with solid electrolyte are used to reduce device size, then energy density is improved, but power capability deteriorates due to poor ionic conductivity
Solution Approach 1:
The patent transitions from conventional two-dimensional planar electrode architecture to a three-dimensional interdigitated structure with vertically stacked electrodes. This dimensional change increases the electrode surface area and reduces the diffusion distance for ions, thereby improving power capability while maintaining the thin film format for high energy density.
Solution Approach 2:
The patent employs porous electrode structures with controlled porosity to enhance the surface area available for electrochemical reactions. The porous architecture allows for better electrolyte penetration and shorter ion transport paths, improving ionic conductivity and power capability without sacrificing the compact thin film design.
2Power
If conventional stacked battery architecture with thick layers is used, then power capability is maintained, but device size increases making it unsuitable for miniaturized devices
Solution Approach 1:
The patent adopts a three-dimensional interdigitated electrode configuration where electrodes are stacked vertically rather than laid out in large planar areas. This vertical stacking reduces the footprint and overall battery volume while maintaining sufficient electrode surface area for adequate power capability.
Solution Approach 2:
The battery is divided into multiple thin film layers stacked in sequence, with each layer contributing to the overall capacity. This segmentation allows the total energy storage to be distributed across multiple thin layers rather than requiring a single thick layer, thus reducing the overall battery volume while maintaining power capability.
3Quantity of substance
If solid electrode materials are used to achieve high energy density, then energy storage capacity is improved, but ionic conductivity deteriorates
Solution Approach 1:
The patent utilizes porous solid electrode materials that provide high surface area for energy storage while allowing efficient electrolyte penetration. The porous structure reduces the effective diffusion distance for ions through the solid electrode material, improving ionic conductivity while maintaining high energy storage capacity in a compact thin film format.
Solution Approach 2:
The patent employs composite electrode structures combining solid active materials with conductive additives and binder systems optimized for thin film applications. These composite materials enhance the ionic conductivity of the solid electrode while maintaining high energy density, resolving the trade-off between energy storage capacity and ionic transport efficiency.
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 solution provides a compact battery architecture that enhances energy density while maintaining power accessibility, addressing the limitations of traditional battery systems in small-scale devices by integrating all components into a three-dimensional nanostructure.
Implementation Method 1
a pinhole-free solid electrolyte layer, ion-conducting but electronically insulating
Implementation Method 2
a pinhole-free solid electrolyte layer, ion-conducting but electronically insulating
Implementation Method 3
a solid bicontinuous monolithic carbon anode having an ordered three-dimensionally continuous network nanostructure
Implementation Method 4
combining a carbon precursor and a structure-directing block copolymer to yield a self-assembled precursor/copolymer composite
Implementation Method 5
an active cathode material selected from the group consisting of sulfur, selenium, redox-active polymer, and a lithium metal oxide
Data Source
AI summary
A solid-state three-dimensional battery assembly includes a solid bicontinuous monolithic carbon anode, a solid electrolyte layer, and a solid cathode. The solid monolithic carbon anode has an ordered three-dimensionally continuous network nanostructure, a length of at least 100 nm, and an average thickness of 3 to 90 nm. The ordered three-dimensionally continuous network nanostructure of the anode defines a plurality of pores having an average diameter of 5 to 100 nm. The solid electrolyte layer is disposed directly on the anode, has an average thickness of 3 to 90 nm, and fills a portion of the pores defined by the ordered three-dimensionally continuous network nanostructure of the anode. The solid cathode is disposed directly on the electrolyte layer, has an average thickness of 3 to 90 nm, and also fills a portion of the pores defined by the ordered three-dimensionally continuous network nanostructure of the anode. Related devices and methods are also provided.