Ceramic Coated Li-Ion Battery Separator for Dendrite Resistance
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Solution Overview
Problem
Current separators in Li-ion batteries are prone to electrical shorts due to lithium dendrite growth, are expensive, and have complex manufacturing methods, limiting the size, weight, and capacity of energy storage devices.
Innovation Solution
A method of forming a ceramic separator layer on the surface of electrodes using a high-rate evaporation process with reactive gases, such as oxygen, to create a thin, low-ionic resistance coating that inhibits dendrite growth and enhances ionic conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If high porosity separators are used to increase ionic conductivity, then ionic conductivity is improved, but electrical shorts occur due to lithium dendrite formation
Solution Approach 1:
The patent applies local quality by creating a ceramic coating layer with specific properties (porosity, composition) only on the separator surface where dendrite contact occurs, rather than changing the entire separator structure. This allows the bulk separator to maintain high porosity for ionic conductivity while the coated surface provides dendrite resistance
Solution Approach 2:
The patent uses composite materials by combining organic separator materials (polyethylene, polyolefin) with inorganic ceramic materials (alumina, silica). This composite structure provides both the high porosity needed for ionic conductivity and the mechanical/dendrite resistance properties of ceramics
2Ease of manufacture
If conventional separator manufacturing methods are used, then separators are available, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the separator manufacturing process with the electrode assembly process by depositing the ceramic coating layer directly onto the separator during battery assembly. This eliminates the need for separate separator production and coating steps, reducing overall manufacturing complexity
Solution Approach 2:
The patent applies self-service by having the separator serve dual functions: providing physical separation between electrodes and serving as a substrate for the ceramic anti-dendrite coating. This eliminates the need for separate functional components
3Ease of manufacture
If conventional separator materials are used, then separators are available, but material cost increases
Solution Approach 1:
The patent uses inexpensive ceramic materials (alumina, silica, magnesia) that can be applied as thin coating layers. These materials are far cheaper than conventional high-performance separator materials, and the thin coating requires minimal material quantity while providing effective dendrite protection
4Weight of moving object
If separator size is reduced to decrease device weight and size, then device weight and size are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical-chemical parameters of the separator by adding a ceramic coating layer with different properties (porosity, mechanical strength, thermal stability). This allows the separator to maintain reduced dimensions while the coating provides the structural integrity and precision needed for small-scale operation
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 ceramic separator layer reduces tortuosity, increases energy density, and provides higher voltage stability and puncture resistance, enabling faster charging and higher capacity energy storage devices with improved manufacturing efficiency.
Implementation Method 1
exposing a metallic material to be deposited on a surface of an electrode structure positioned in a processing region to an evaporation process
Implementation Method 2
reacting the reactive gas and the evaporated metallic material to deposit a ceramic separator layer on the surface of the electrode structure
Data Source
AI summary
Implementations of the present disclosure generally relate to separators, high performance electrochemical devices, such as, batteries and capacitors, including the aforementioned separators, and methods for fabricating the same. In one implementation, a method of forming a separator for a battery is provided. The method comprises exposing a metallic material to be deposited on a surface of an electrode structure positioned in a processing region to an evaporation process. The method further comprises flowing a reactive gas into the processing region. The method further comprises reacting the reactive gas and the evaporated metallic material to deposit a ceramic separator layer on the surface of the electrode structure.