Ceramic Fiber Separator Layer for Heat-Stable Fast-Charging Cells
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Solution Overview
Problem
Conventional polymer-based separator membranes in electrochemical energy storage devices suffer from limitations such as limited thermal stability, mechanical strength, poor wetting by electrolytes, and poor resistance to dendrite penetration, which become exacerbated under conditions of fast charging, high temperatures, and prolonged cycling.
Innovation Solution
The use of ceramic-comprising separator layers, particularly made from small ceramic fibers or flakes, which are flexible, thermally stable, and offer better mechanical properties, enhancing ion transport and safety by preventing internal shorts and dendrite penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer-based separator membranes are used, then flexibility and ease of manufacture are improved, but thermal stability and mechanical strength deteriorate
Solution Approach 1:
The patent employs composite materials by combining polymer matrix with ceramic particles (such as alumina, silica, or titania) to create a separator membrane that exhibits both the flexibility and ease of manufacture of polymers and the thermal stability of ceramics. The ceramic particles are dispersed within the polymer matrix, creating a composite structure that leverages the advantages of both material types while mitigating their individual weaknesses.
2Ease of manufacture
If polymer-based separator membranes are used, then flexibility and ease of manufacture are improved, but mechanical strength deteriorates
Solution Approach 1:
The composite structure of polymer matrix reinforced with ceramic particles provides enhanced mechanical strength while maintaining flexibility. The ceramic particles act as reinforcing agents that increase the overall mechanical properties of the separator membrane, preventing it from becoming too weak when produced in thin formats.
Solution Approach 2:
The patent utilizes porous structures in the separator membrane design, where the porous network formed by the ceramic particle dispersion provides both mechanical reinforcement and pathways for ion transport. The porous architecture contributes to mechanical strength while allowing the membrane to remain flexible and manufacturable.
3Quantity of substance
If separator membrane thickness is reduced to increase energy density, then energy density is improved, but mechanical strength and safety deteriorate
Solution Approach 1:
The ceramic-polymer composite structure enables the production of ultra-thin separator membranes that maintain adequate mechanical strength. The ceramic particles provide reinforcement that compensates for the reduced thickness, allowing the membrane to be thin enough to achieve high energy density while remaining strong enough to ensure safety and prevent dendrite penetration.
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-comprising separator layers provide improved mechanical strength, thermal stability, and faster ion transport, enabling safer and higher energy density performance in batteries and capacitors, especially under conditions of fast charging and high temperatures.
Implementation Method 1
ceramic-comprising separator layers, particularly made from small ceramic fibers or flakes, which are flexible, thermally stable, and offer better mechanical properties
Implementation Method 2
allowing transport of electrolyte ions between these electrodes
Implementation Method 3
offer better mechanical properties, enhancing ion transport and safety by preventing internal shorts and dendrite penetration
Data Source
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AI summary
An embodiment is directed to a separator with a ceramic-comprising separator layer. The ceramic-comprising separator layer comprises porous metal oxide fibers with diameters in the range from around 3 nm to around 2 microns, aspect ratios in the range from around 20 to around 100,000, and a total open pore volume among the porous metal oxide fibers in the range from around 0.01 cm3/g to around 1 cm3/g.