Open-Cell Zinc Sponge Anodes With Controlled Porosity

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Solution Overview

Problem

Existing production processes for three-dimensional zinc electrodes in rechargeable batteries face limitations in setting pore size and structure, leading to non-uniform charge distribution and potential short circuits due to dendrite growth and shape changes.

Innovation Solution

A pressure-difference method is employed to create open-cell metal sponge structures using molten metals and placeholders, allowing for adjustable pore sizes and shapes without binders, enabling a uniform and dimensionally stable anode structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional powder pressing or sintering methods are used to prepare zinc electrodes, then the electrode structure is formed, but the pore size and structure cannot be consistently controlled, leading to non-uniform charge distribution and dendrite growth

Engineering Contradiction:

Improvepore size controlVSAvoidcharge distribution uniformity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The invention uses porous placeholders with controlled size and shape (such as porous beads or granules) as templates during the casting process. These placeholders create a predefined porous structure in the zinc electrode, enabling consistent pore size control and uniform charge distribution throughout the electrode structure.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention changes the physical state of zinc from powder to molten metal, allowing the metal to flow and fill the spaces around placeholders uniformly. By controlling the temperature and pressure parameters during casting, the process achieves consistent pore structure and uniform zinc distribution, eliminating dendrite formation.

Inventive Principle:

Principle #35Parameter changes

2Shape

If binders are used to retain powder structures, then the electrode maintains its shape, but the structure is no longer consistently metallic and charge dissipation becomes non-uniform

Engineering Contradiction:

Improvestructure retentionVSAvoidcharge dissipation uniformity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The invention exploits the phase transition of zinc from solid powder to molten metal and back to solid. The molten zinc flows around placeholders and solidifies into a consistently metallic structure upon cooling, eliminating the need for organic binders while maintaining shape integrity through the rigid metallic framework.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The placeholders serve as intermediaries during the casting process, providing a template structure that guides zinc solidification. These placeholders are subsequently removed, leaving a clean metallic structure without binder contamination, ensuring uniform charge dissipation throughout the electrode.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If zinc powder is pressed or admixed with additives and pressed, then the electrode is formed, but the process requires binders and complex processing steps

Engineering Contradiction:

Improveprocess simplicityVSAvoidprocessing steps

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention replaces the mechanical pressing and mixing process with a thermal casting process. Instead of mechanically compacting powder with binders, molten zinc is poured into a mold containing placeholders, allowing gravity and thermal energy to form the electrode structure in a single step, significantly simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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

The method produces stable anodes with controlled porosity and reduced dendrite growth, enhancing cycle stability and safety in batteries by maintaining uniform zinc deposition and preventing short circuits.

Implementation Method 1

applying a pressure difference between the first opening and the second opening of the casting mold, whereby the molten metal gets into the interior of the casting mold

Methodology Applied

Scientific EffectPressure difference: Pressure Gradient

Implementation Method 2

allowing the molten metal to solidify in the interior of the casting mold

Methodology Applied

Scientific EffectSolidification: Phase Change

Data Source

PatentUS20250319514A1Method for producing a three-dimensional metal molding body having an open-cell metal sponge structure

Publication Date: 2025.10.16 GRILLO WERKE AG

AI summary

The present invention relates to a method for producing an open-cell metal molding body from zinc, tin, lead, indium, aluminum, magnesium or bismuth, or from alloys of such metals, and to the use of the obtained metal molding body as an anode.