Composite Cathode With Gel Polymer Electrolyte for Better Interface Contact

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Solution Overview

Problem

Lithium-ion batteries with liquid electrolytes face safety concerns due to thermal runaway and leakage, while solid-state batteries offer higher energy density but are costly and inefficient due to low deformability of their layers, limiting mainstream adoption.

Innovation Solution

A composite cathode material comprising a gel polymer electrolyte and particles of cathode material, which enhances interfacial contact and reduces manufacturing costs by eliminating the need for a separate electrolyte layer, using a polymer matrix with lithium salt and solvent, and inorganic fillers for improved mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If solid-state electrochemical cells are used to achieve higher energy density, then energy density is improved, but manufacturing cost increases and manufacturing time increases

Engineering Contradiction:

Improveenergy densityVSAvoidmanufacturing cost

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent combines the cathode material and electrolyte into a single composite cathode layer, where cathode particles are embedded in a polymer matrix that serves as the electrolyte. This eliminates the need for separate cathode and electrolyte layers, reducing manufacturing steps and costs while maintaining high energy density.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a composite material structure where cathode particles are dispersed within a polymer electrolyte matrix. This composite approach allows simultaneous achievement of high energy density (from cathode material) and ease of manufacture (from polymer processing capabilities).

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If solid-state electrochemical cells are used to achieve higher energy density, then energy density is improved, but manufacturing time increases

Engineering Contradiction:

Improveenergy densityVSAvoidmanufacturing time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

By merging cathode and electrolyte functions into one composite layer, the patent eliminates sequential manufacturing steps required for separate layers, thereby reducing total manufacturing time while maintaining high energy density.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If solid cathode layers with low deformability are used, then structural stability is improved, but interfacial contact between layers deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoidinterfacial contact

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent changes the physical state of the electrolyte from rigid solid to soft polymer matrix, which can deform and conform to cathode particles. This improves interfacial contact and reliability while the composite structure maintains overall structural stability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The polymer electrolyte matrix acts as a flexible medium that can deform to maintain good contact with cathode particles and adjacent layers, improving interfacial contact compared to rigid solid electrolytes.

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of manufacture

If liquid electrolyte is used in lithium-ion batteries, then ease of manufacture is improved, but safety deteriorates due to thermal runaway and leakage

Engineering Contradiction:

Improveease of manufactureVSAvoidsafety

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the electrolyte from liquid to polymer gel state, which eliminates leakage risks and improves safety while maintaining manufacturing simplicity. The polymer matrix retains ion conductivity without the hazards of liquid electrolytes.

Inventive Principle:

Principle #35Parameter changes

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 composite cathode material improves ion transport efficiency, reduces manufacturing time and costs, and increases energy density while maintaining performance, making electrochemical cells simpler and more cost-effective.

Implementation Method 1

The solvent acts as a plasticizer, so may also be referred to as a plasticizer

Methodology Applied

Scientific EffectPlasticizer effect:

Implementation Method 2

The gel polymer electrolyte acts as a matrix which holds the particles of cathode material

Methodology Applied

Scientific EffectMatrix structure:

Implementation Method 3

The polymer matrix is crosslinked

Methodology Applied

Scientific EffectCrosslinking:

Implementation Method 4

The fluid nature of the gel polymer electrolyte as part of the composite cathode material means that it may act as a planarizing layer during manufacture of a laminate electrochemical cell

Methodology Applied

Scientific EffectPlanarizing effect:

Data Source

PatentUS20230411621A1Composite cathode material

Publication Date: 2023.12.21 DYSON TECH LTD

AI summary

A composite cathode material includes a gel polymer electrolyte and particles of a cathode material. The particles of the cathode material are arranged in the gel polymer electrolyte.