Systems and methods for electrical energy storage

Patent metadata

Field	Value
Publication number	US-2022209277-A1
Application number	US-202217697375-A
Country	US
Kind code	A1
Filing date	Mar 17, 2022
Priority date	Nov 20, 2015
Publication date	Jun 30, 2022
Grant date	—

Abstract

The present disclosure relates to an electrical energy storage apparatus. The apparatus has an interpenetrating, three dimensional periodic structure formed from an ionically conductive solid electrolyte material having a plurality of interpenetrating, non-planar channels. The interpenetrating, non-planar channels are made up of a first plurality of channels filled with an anode material, a second plurality of channels adjacent the first plurality of channels and interpenetrating with the first plurality of channels, and filled with a cathode material, and a third plurality of channels adjacent to, and interpenetrating with, one of the first and second pluralities of channels, and filled with a material to form a separator. The first, second and third channels form a spatially dense, three dimensional structure. A first non-flat current collector layer is incorporated which is in communication with the first plurality of channels, and which forms a first electrode. A second non-flat current collector layer is incorporated which is in communication with the second non-planar channel, and which forms a second electrode.

First claim

What is claimed is:

1 . An electrical energy storage apparatus, comprising:
an interpenetrating, three dimensional structure formed from an ionically conductive solid electrolyte material having a plurality of interpenetrating, non-planar channels, the interpenetrating, non-planar channels including:
a first plurality of channels filled with an anode material;
a second plurality of channels adjacent the first plurality of channels and interpenetrating the first plurality of channels, and filled with a cathode material;
a third plurality of channels adjacent, and interpenetrating, one of the first and second pluralities of channels and filled with a material to form a separator; and
said first, second and third channels forming a spatially dense, three dimensional structure;
a first non-flat current collector layer in communication with the first plurality of channels, and forming a first electrode; and a second non-flat current collector layer in communication with the second non-planar channel and forming a second electrode.

2 . The apparatus of claim 1 , wherein the anode material includes an electrically conductive filler material to improve electrical conductivity of the anode material.

3 . The apparatus of claim 1 , wherein the cathode material includes an electrically conductive filler material to improve electrical conductivity of the cathode material.

4 . The apparatus of claim 1 , wherein the three dimensional periodic structure comprises one of:
a gyroid; a double gyroid; a Schwartz surface; kelvin foam; octet truss, and a kagome lattice; a Neovius surface; an N14 Surface; an N26 Surface; an N38 Surface; a Diamond surface; and a Double Diamond surface.

5 . An electrical energy storage apparatus, comprising:
an interpenetrating, three dimensional periodic structure formed from an ionically conductive solid electrolyte material having a plurality of interpenetrating, non-planar channels, the plurality of interpenetrating, non-planar channels including:
a first plurality of channels of an anode material;
a second plurality of channels adjacent the first plurality of channels and interpenetrating the first plurality of channels, and being of a cathode material;
a third plurality of channels adjacent, and interpenetrating, one of the first and second pluralities of channels and being of a material to form a separator; and
a first current collector layer in communication with the first plurality of channels, and forming a first electrode; a second current collector layer in communication with the second non-planar channel and forming a second electrode; and wherein the interpenetrating, three dimensional periodic structure comprises one of: a gyroid; a double gyroid; a Schwartz surface; kelvin foam; octet truss; a kagome lattice; a Neovius surface; an N14 Surface; an N26 Surface; an N38 Surface; a Diamond surface; and a Double Diamond surface.

6 . The apparatus of claim 5 , wherein each one of the first plurality of channels is filled with the anode material.

7 . The apparatus of claim 6 , wherein the anode material includes an electrically conductive filler material to improve electrical conductivity of the anode material.

8 . The apparatus of claim 5 , wherein each one of the second plurality of channels is filled with the cathode material.

9 . The apparatus of claim 8 , wherein the cathode material includes an electrically conductive filler material to improve electrical conductivity of the cathode material.

10 . The apparatus of claim 5 , wherein the first current collector layer comprises a non-flat current collector layer.

11 . The apparatus of claim 5 , wherein the second current collector layer comprises a non-flat current collector layer.

12 . The apparatus of claim 5 , wherein the interpenetrating, three dimensional periodic structure is formed using an additive manufacturing process.

13 . A method for forming an electrical energy storage apparatus configured as a three dimensional structure, the method comprising:
forming an interpenetrating, three dimensional periodic structure having a first plurality of non-planar channels and a second plurality of non-planar channels in proximity to the first plurality of non-planar channels, the first and second pluralities of non-planar channels further being interpenetrating; filling each one of the first plurality of non-planar channels with an anode material to form an anode; filling each one of the second plurality of non-planar channels with a cathode material to form a cathode; filling areas adjacent the first and second pluralities of non-planar channels with an electrolyte; forming a first electrode to operate as a current collector, which is in electrical contact with portions of the anode material; and forming a second electrode which is in electrical contact with portions of the cathode material.

14 . The method of claim 13 , further comprising adding electrically conductive filler material to the anode material before filling the first plurality of non-planar channels.

15 . The method of claim 13 , further comprising adding electrically conductive filler material to the cathode material before filling the second plurality of non-planar channels.

16 . The method of claim 13 , wherein the method forms an electrical energy storage device having at least one of the following configurations:
a gyroid; a double gyroid; a Schwartz surface; kelvin foam; an octet truss; a kagome lattice; a Neovius surface; an N14 Surface; an N26 Surface; an N38 Surface; a Diamond surface; and a Double Diamond surface.

17 . The method of claim 13 , wherein the operation of forming the interpenetrating three dimensional structure comprises using a three dimensional printing process.

18 . The method of claim 13 , wherein the first electrode is formed by a first current collector layer of material, the first current collector layer of material being formed as a non-flat layer of material in interpenetrating engagement with the anode material.

19 . The method of claim 13 , wherein the second electrode is formed by a second current collector layer of material, the second current collector layer of material being formed as a non-flat layer of material in interpenetrating engagement with the cathode material.

Assignees

• L Livermore Nat Security Llc
• Univ Texas

Inventors

• Duoss Eric
• Biener Juergen
• Campbell Patrick
• Jackson Julie A
• Oxberry Geoffrey M
• Spadaccini Christopher
• Stadermann Michael
• Zhu Cheng
• TREMBACKI Bradley
• Murthy Jayathi
• Merrill Matthew

Classifications

• B33Y80/00

  Products made by additive manufacturing · CPC title

• H01G11/52

  Separators · CPC title

• H01G11/26

  characterised by their structure, e.g. multi-layered, porosity or surface features · CPC title

• H01M10/02 Primary

  Details (of electrodes H01M4/00; of non-active parts H01M50/00) · CPC title

• H01G11/28

  arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives · CPC title