Systems and methods for minimizing and preventing dendrite formation in electrochemical cells

Patent metadata

Field	Value
Publication number	US-2026051549-A1
Application number	US-202519367782-A
Country	US
Kind code	A1
Filing date	Oct 23, 2025
Priority date	Dec 16, 2022
Publication date	Feb 19, 2026
Grant date	—

Abstract

Embodiments described herein relate to electrochemical cells with dendrite prevention mechanisms. In some aspects, an electrochemical cell can include an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, the cathode having a first thickness at a proximal end of the cathode and a second thickness at a distal end of the cathode, the second thickness greater than the first thickness, a first separator disposed on the anode, a second separator disposed on the cathode, an interlayer disposed between the first separator and the second separator, the interlayer including electroactive material and having a proximal end and a distal end, and a power source electrically connected to the proximal end of the cathode and the proximal end of the interlayer, the power source configured to maintain a voltage difference between the cathode and the interlayer below a threshold value.

First claim

1 . A method of operating an electrochemical cell, the electrochemical cell including an anode, a cathode, a first separator disposed on the anode, a second separator disposed on the cathode, and an interlayer disposed between the first separator and the second separator, the method comprising:
measuring a voltage between the anode and the interlayer; detecting formation of a dendrite; and adjusting a potential of the interlayer towards a potential of the cathode via a circuit coupled to at least the interlayer and the cathode, such that the formation of the dendrite is mitigated.

2 . The method of claim 1 , wherein the anode includes a lithium metal anode.

3 . The method of claim 1 , wherein the circuit includes at least one of a transistor, a BJT, a MOSFET, or other switching device.

4 . The method of claim 1 , wherein the circuit includes a diode.

5 . The method of claim 4 , wherein the circuit includes a switch configured to bypass the diode.

6 . The method of claim 1 , wherein detecting the formation of the dendrite is via a system controller.

7 . The method of claim 6 , wherein adjusting the potential of the interlayer is via the system controller.

8 . The method of claim 1 , wherein detecting the formation of the dendrite is via at least one of actively modulating, pulsing, or alternating a controlled potential of the interlayer.

9 . The method of claim 1 , wherein the interlayer includes a conductive material.

10 . The method of claim 1 , wherein the interlayer includes at least one of activated carbon, hard carbon, soft carbon, conductive carbon particles, carbon black, graphitic carbon, carbon fibers, carbon microfibers, vapor-grown carbon fibers (VGCF), fullerenic carbons including “buckyballs”, carbon nanotubes (CNTs), multiwall carbon nanotubes (MWNTs), single wall carbon nanotubes (SWNTs), graphene, graphene sheets, aggregates of graphene sheets, or materials comprising fullerenic fragments.

11 . A method of operating an electrochemical cell, the electrochemical cell including an anode, a cathode, a first separator disposed on the anode, a second separator disposed on the cathode, an interlayer disposed between the first separator and the second separator, and a controller, the method comprising:
measuring a voltage between the anode and the interlayer; detecting formation of a dendrite; receiving, via the controller, a signal corresponding to the formation of the dendrite; and causing, via the controller, a voltage of the interlayer to be adjusted towards a voltage of the cathode to remediate formation of the dendrite.

12 . The method of claim 11 , wherein measuring the voltage between the anode and the interlayer is via a circuit electrically coupled to the anode and the interlayer.

13 . The method of claim 12 , wherein the circuit includes at least one of a transistor, a BJT, a MOSFET, or other switching device.

14 . The method of claim 12 , further comprising:
passing a current to the interlayer via a dendrite prevention pullup control module.

15 . The method of claim 12 , wherein the circuit includes a diode.

16 . The method of claim 15 , wherein the circuit includes a switch configured to bypass the diode.

17 . The method of claim 11 , wherein the interlayer includes a conductive material.

18 . A method of operating an electrochemical cell, the electrochemical cell including an anode, a cathode, a first separator disposed on the anode, a second separator disposed on the cathode, an interlayer disposed between the first separator and the second separator, and a controller, the method comprising:
measuring a first voltage between the anode and the cathode; measuring a second voltage between the anode and the interlayer; designating, via the controller, a desired voltage differential based on the first voltage and the second voltage; and initiating, via the controller, a corrective action based at least on the first voltage and the desired voltage differential to mitigate or remediate dendrite formation.

19 . The method of claim 18 , further comprising:
hardware filtering of the second voltage to detect dendrite formation.

20 . The method of claim 19 , wherein the hardware filtering is via at least one of high pass, low pass, band pass, proportional, integration, differential, amplitude, or frequency conversion.

21 . The method of claim 18 , wherein measuring the second voltage is via a circuit electrically coupled to the anode and the interlayer.

22 . The method of claim 21 , wherein the circuit includes at least one of a transistor, a BJT, a MOSFET, or other switching device.

23 . The method of claim 21 , further comprising:
passing a current to the interlayer via a dendrite prevention pullup control module.

24 . The method of claim 21 , wherein the circuit includes a diode.

25 . The method of claim 24 , wherein the circuit includes a switch configured to bypass the diode.

26 . A method of operating an electrochemical cell, the electrochemical cell including an anode, a cathode, a first separator disposed on the anode, a second separator disposed on the cathode, and an interlayer disposed between the first separator and the second separator, the method comprising:
measuring a first voltage between the anode and the cathode; measuring a second voltage between the anode and the interlayer; and detecting formation of a dendrite via a proportional-integral (PI) loop to measure a difference between the first voltage and the second voltage.

27 . The method of claim 26 , further comprising:
initiating a corrective action based at least on the detection of formation of the dendrite.

28 . The method of claim 26 , wherein detecting the formation of the dendrite is via a system controller.

29 . The method of claim 26 , wherein detecting the formation of the dendrite is via at least one of actively modulating, pulsing, or alternating a controlled potential of the interlayer.

30 . The method of claim 26 , further comprising:
passing a current to the interlayer via a dendrite prevention pullup control module.

Assignees

• 24M Tech Inc

Inventors

• Chen Junzheng
• Ota Naoki
• Hartzog Chad Alan
• Liu Xiaoming
• Brouwer Michelle Robyn
• D'Angelo Anthony
• Salazar Daniel
• Hans Timothy Allen
• Song Junhua

Classifications

• H02J7/80

  including monitoring or indicating arrangements · CPC title

• H01M4/1395

  of electrodes based on metals, Si or alloys · CPC title

• H01M4/1393

  of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx · CPC title

• H01M4/1391

  of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx · CPC title

• H01M4/134

  Electrodes based on metals, Si or alloys · CPC title