Tuning battery electrode porosity technical field

A method of calculating a desired porosity of battery electrodes of a battery during manufacturing of the battery electrodes using an electrochemical model and a thermal model of a battery comprising:

• determining energy and current requirements of the battery;
• determining battery characteristics in response to said energy and current requirements;
• determining porosity of the battery electrodes by solving equations within the electrochemical model and the thermal model;
• and
• varying porosity of the battery electrodes until voltage potential across the battery varies by less then a predetermined tolerance factor for an operating range state of charge.

A method of calculating a desired porosity of battery electrodes of a battery during manufacturing of the battery electrodes using a first-principles battery model comprising:

• determining energy and current requirements of the battery;
• determining battery characteristics in response to said energy and current requirements;
• preparing said battery characteristics and said energy and current requirements for use in the first-principles battery model to obtain prepared battery characteristics;
• determining porosity of the battery electrodes by solving equations within the first-principles battery model using said prepared battery characteristics and said energy and current requirements;
• varying porosity of the battery electrodes until voltage potential across the battery varies by less then a predetermined tolerance factor for an operating range state of charge;
• creating a paste mixture in response to said optimum battery electrode porosity;
• applying said paste mixture to a grid to form an electrode;
• and
• curing said electrode.

A method of calculating a desired porosity of battery electrodes of a battery during manufacturing of the battery electrodes using a first-principles battery model comprising:

• determining battery capacity, discharge performance, and cycle life;
• determining battery characteristics in response to said battery capacity, said discharge performance, and said cycle life;
• preparing said battery characteristics, said battery capacity, said discharge performance, and said cycle life values for use in the first-principles battery model to obtain prepared battery characteristics;
• determining porosity of the battery electrodes by solving equations within the first-principles battery model that represent electrolyte displacement, electrolyte flow, electrolyte permeability, electrolyte diffusion, and electrolyte saturation using said prepared battery characteristics, said battery capacity, said discharge performance, and said cycle life values;
• varying porosity of the battery electrodes until voltage potential across the battery varies by less then a predetermined tolerance factor for an operating range state of charge;
• creating a paste mixture in response to said optimum battery electrode porosity;
• applying said paste mixture to a grid to form an electrode;
• and
• curing said electrode.