Biodegradable Gel Polymer Electrolyte Extrusion for Uniform Battery Layers
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Solution Overview
Problem
Current battery technologies lack environmentally friendly and biodegradable options, and existing methods for producing gel polymer electrolytes in batteries suffer from issues such as non-uniform thickness, air bubbles, and inadequate pile height, leading to structural defects and performance irregularities.
Innovation Solution
A method for producing a biodegradable electrolyte layer using an extrusion process, involving dispensing a gel polymer electrolyte composition with controlled viscosity and curing under ambient conditions, which includes a hydrogel of a copolymer and salt, and subjecting it to UV radiation for uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing method is used to deposit gel polymer electrolyte, then manufacturing process is simple, but film uniformity is poor with non-uniform thickness, air bubbles, and inadequate pile height
Solution Approach 1:
The patent replaces the screen printing mechanical deposition method with a digital light processing (DLP) photopolymerization method. The DLP system uses digital light patterns to selectively cure the electrolyte resin, allowing precise control over film thickness and uniformity while eliminating the mechanical defects (air bubbles, non-uniform thickness) associated with screen printing. This substitution of mechanical deposition with digital light-based curing resolves the contradiction between manufacturing simplicity and film uniformity.
2Reliability
If conventional battery materials are used, then battery performance is reliable, but environmental harm increases due to non-biodegradability
Solution Approach 1:
The patent changes the chemical composition parameters of the battery electrolyte by using biodegradable polymers (such as polylactic acid, polyglycolic acid, or their copolymers) instead of conventional non-biodegradable materials. This parameter change in material composition maintains the electrolyte's functional performance while introducing biodegradability, thereby reducing environmental harm. The electrolyte resin is specifically formulated with biodegradable polymer matrices that can decompose naturally after use.
3Productivity
If electrolyte composition is dispensed without pausing, then production efficiency is high, but coalescence is insufficient leading to poor film quality
Solution Approach 1:
The patent incorporates a pausing step in the dispensing process that allows the electrolyte composition to coalesce before final curing. This preliminary coalescence action occurs during the dispensing phase, where the material is deposited and given time to self-level and merge properly. By performing this coalescence action preliminarily before the curing step, the method ensures adequate film quality and uniformity while maintaining overall production efficiency, as the pause is integrated into the automated dispensing-curing cycle.
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 method produces a bubble-free, uniformly thick electrolyte layer with consistent pile height, enhancing the structural integrity and performance of biodegradable batteries while being environmentally friendly.
Implementation Method 1
curing the electrolyte composition... subjecting it to UV radiation for uniformity
Data Source
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AI summary
An electrochemical device is disclosed, which includes an anode and a cathode. The electrochemical device also includes an extruded electrolyte composition disposed between the anode and the cathode. The cathode and/or the anode of the electrochemical device may be disposed in a stacked geometry or in a lateral x-y plane geometry. The electrolyte composition may include a gel polymer electrolyte. The electrolyte composition is disposed between the anode and the cathode in a laterally non-continuous pattern. A method of producing an electrolyte layer of an electrochemical device is also disclosed.