Anodized Metal Oxide Battery Separator with Nanometer Through-Pores
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Solution Overview
Problem
Conventional battery separators made from polymers suffer from mechanical integrity issues, inadequate resistance to contamination, and limited chemical and electrochemical stability, which degrade battery performance and safety, particularly in lithium-ion batteries.
Innovation Solution
The use of porous anodized metal oxide separators with through-pores, fabricated through an electrochemical anodization process, which provides enhanced mechanical toughness, chemical stability, and reduced ionic resistance, suitable for both two-dimensional and three-dimensional battery architectures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polymeric separators are used to maintain mechanical integrity, then the separator thickness must be increased, but this degrades the battery's gravimetric and volumetric energy density
Solution Approach 1:
The patent employs porous anodized metal oxide layers as separators, which provide both mechanical integrity and ionic transport pathways. The porous structure allows ions to pass through while the metal oxide framework maintains structural strength, eliminating the need for thick polymeric separators and thereby improving energy density.
Solution Approach 2:
The separator is constructed as a composite structure with a metal substrate and an anodized metal oxide layer. This composite approach combines the mechanical strength of the metal substrate with the chemical stability and porosity of the metal oxide layer, achieving both mechanical integrity and high energy density.
2Quantity of substance
If polymeric separators are used, then the separator may provide adequate porosity, but the resistance to puncture by metallic and particulate contamination is inadequate
Solution Approach 1:
The anodized metal oxide layer forms a porous structure that provides adequate porosity for ion transport while the metal oxide material itself offers superior puncture resistance compared to polymeric materials, improving reliability against metallic and particulate contamination.
Solution Approach 2:
The patent changes the material parameter from organic polymer to inorganic metal oxide, which fundamentally alters the mechanical properties including puncture resistance, while maintaining the necessary porosity through controlled anodization processes.
3Ease of operation
If polymeric separators are used, then the separator may be flexible, but the chemical and electrochemical stability is insufficient, leading to degradation at high cathodic potentials
Solution Approach 1:
The patent changes the chemical composition from organic polymer to inorganic metal oxide, which dramatically improves chemical and electrochemical stability. The metal oxide material remains stable at high cathodic potentials where polymeric materials would degrade, enabling higher operating voltages and capacities.
Solution Approach 2:
The composite structure of metal substrate with anodized metal oxide layer provides both the necessary flexibility for battery assembly and superior chemical stability, as the metal oxide layer is inherently resistant to degradation in the battery electrolyte environment.
4Quantity of substance
If the separator thickness is reduced to improve energy density, then the mechanical integrity and protection against shorting are compromised
Solution Approach 1:
The porous anodized metal oxide layer provides effective separation and protection against shorting at reduced thickness, as the porous structure creates multiple tortuous pathways that prevent direct contact between electrodes while still allowing ion transport.
Solution Approach 2:
Changing from polymeric to metal oxide material allows for thinner separator design with maintained or improved protective function, as the metal oxide provides superior mechanical strength and puncture resistance per unit thickness compared to polymers.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The porous anodized metal oxide separators improve battery safety and performance by offering higher energy densities, reduced risk of shorting, and increased mechanical stability while maintaining a thinner profile, enabling better ion transport and protection against dendrite formation.
Implementation Method 1
The starting metal layer is then anodized so as to form the porous anodized metal oxide separator layer
Implementation Method 2
fabricated through an electrochemical anodization process
Implementation Method 3
allowing for ionic transport through the electrolyte in the pores
Implementation Method 4
The porous anodized metal oxide separators improve battery safety and performance by offering higher energy densities, reduced risk of shorting, and increased mechanical stability while maintaining a thinner profile, enabling better ion transport
Data Source
AI summary
A process of manufacturing a lithium ion battery that includes an anode and a cathode. In the process, a cathodic electrode layer and a composite structure are assembled to form a stack. The stack includes the cathodic electrode layer, an anodic electrode layer and a separator layer between the cathodic electrode layer and the anodic electrode layer. The composite structure includes the anodic electrode layer and the separator layer. The separator layer includes a porous anodized metal oxide layer containing substantially straight and parallel nanometer scale through-pores haying a diameter of less than 100 nm. The anodized metal oxide of the porous anodized metal oxide layer is selected from the group consisting of aluminum oxide, titanium oxide, zirconium oxide, niobium oxide, tungsten oxide, tantalum oxide, and hafnium oxide.