Systems and methods for electrical energy storage

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.

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.