USPTO Patent Granted for Porous Electrodes in Batteries

ChangeBridge: Patent Grants - Batteries (H01M)

Published March 24th, 2026

Detected March 26th, 2026

Summary

The USPTO has granted a patent (US12586774B2) for a method of producing porous electrodes for electrochemical devices, such as lithium-ion batteries, without using a binder. The patent was granted to assignee I-TEN and covers systems and methods for manufacturing these electrodes and related battery designs.

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What changed

The United States Patent and Trademark Office (USPTO) has granted patent US12586774B2 for a novel method of creating porous electrodes for electrochemical devices, including lithium-ion batteries. The invention, assigned to I-TEN, focuses on producing electrodes with high porosity, particularly mesoporosity, without the need for a binder. The process involves depositing a colloidal suspension of nanoparticles onto a substrate using various methods, followed by drying and potential consolidation steps like pressing or heat treatment to improve structural integrity and conductivity. A key aspect is the heat treatment's role in forming a porous structure that enhances ion mobility.

This patent grant represents a new intellectual property development in battery technology. While it does not impose direct compliance obligations on regulated entities, it may influence future research and development, manufacturing processes, and supply chains within the battery and energy storage sectors. Companies involved in battery component manufacturing or energy storage solutions should be aware of this patented technology, as it could impact their product development and intellectual property strategies. No immediate actions are required from a compliance perspective, but monitoring patent landscapes in this area is advisable for strategic planning.

Source document (simplified)

← USPTO Patent Grants

Porous electrodes for electrochemical devices

Grant US12586774B2 Kind: B2 Mar 24, 2026

Assignee

I-TEN

Inventors

Fabien Gaben

Abstract

A system and method for producing a porous electrode with a high level of porosity, preferably mesoporosity, without the use of a binder. The electrode is formed by depositing a layer on a substrate from a colloidal suspension containing aggregated or agglomerated nanoparticles. Deposition methods include electrophoresis, ink-jet printing, doctor blade, roll coating, curtain coating, or dip-coating. The process includes drying and may involve additional consolidation steps such as pressing and/or heat treatment to enhance structural integrity, electrical conductivity, and adhesion. The heat treatment induces partial coalescence of nanoparticles, creating a three-dimensional porous structure that facilitates ion mobility. A thin coating of an electrically insulating or ion-conductive material may be applied to reduce interfacial reactions. The resulting porous electrode may be used in energy storage applications, such as lithium-ion batteries. The invention also includes a method for manufacturing batteries utilizing these electrodes and related battery designs.

CPC Classifications

H01M 4/0404 H01M 4/0428 H01M 4/043 H01M 4/0457 H01M 4/131 H01M 4/136 H01M 4/1391 H01M 4/1397 H01M 4/366 H01M 4/485 H01M 4/505 H01M 4/525 H01M 4/5825 H01M 10/0525 H01M 10/0585 H01M 2004/021 H01G 11/24 H01G 11/30