Composite Solid Electrolyte Assembly for Wrinkle-Free Lithium-Ion Cells
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Solution Overview
Problem
Current lithium-ion battery preparation processes face challenges such as wrinkles in the separator leading to lithium dendrite formation and safety issues, along with the need for precise alignment and high dimensional accuracy during stacking, which complicates the manufacturing process.
Innovation Solution
The method involves forming a positive and negative electrode composite structure by laminating composite solid electrolyte membranes on the electrode sheets using a hot pressing process, allowing for better bonding and alignment without precise surface matching, and then stacking these structures with additional membranes for insulation, followed by pressing, trimming, and shaping to create a stable lithium-ion battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stacking equipment is used to stack electrode sheets and separator alternately, then the battery structure can be formed, but wrinkles occur in the separator causing lithium dendrite formation and safety issues
Solution Approach 1:
The invention divides the battery structure into composite units where each unit consists of electrode sheets pre-bonded to solid electrolyte membranes. This segmentation allows each composite unit to be manufactured separately with proper bonding, eliminating the wrinkle formation issue that occurs when trying to stack separate thin separator layers. The composite structure ensures the electrolyte membrane is properly supported and free of wrinkles during assembly.
Solution Approach 2:
The solid electrolyte membrane is pre-bonded to the electrode sheets before stacking, creating a robust composite structure. This preliminary bonding action prevents the separator from developing wrinkles during the subsequent stacking process, as the membrane is already securely attached to the electrode sheets and maintains its flat configuration.
2Manufacturing precision
If conventional stacking process is used without surface bonding preparation, then stacking can be performed, but high dimensional accuracy is required for accurate alignment which complicates the process
Solution Approach 1:
The invention merges the bonding function with the stacking process by using the solid electrolyte membrane as both the separator and the bonding agent. The membrane is applied to the electrode sheet surface and simultaneously serves as the interface for stacking, eliminating the need for separate surface preparation and alignment steps. This integration reduces the requirement for high dimensional accuracy in the stacking equipment.
3Ease of manufacture
If fluid solid electrolyte is used with injection or coating method, then the electrolyte can be formed on electrode sheet surface, but a coating machine is required making the process complex and difficult to control
Solution Approach 1:
The invention changes the physical state parameter of the solid electrolyte from fluid to solid form. This parameter change allows the electrolyte to be applied as a solid membrane through hot pressing or lamination processes, which are simpler and more controllable than fluid injection or coating methods. The solid membrane maintains its shape and position during application, eliminating the need for complex coating equipment and process control systems.
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
This approach simplifies the manufacturing process, reduces the risk of lithium dendrite formation, and enhances the structural integrity and safety of the battery by ensuring good bonding and insulation between electrodes, while accommodating larger dimensional errors and improving the utilization of internal space.
Implementation Method 1
forming a positive and negative electrode composite structure by laminating composite solid electrolyte membranes on the electrode sheets using a hot pressing process, allowing for better bonding and alignment
Data Source
AI summary
A lithium-ion battery comprises a positive electrode sheet, a composite solid electrolyte membrane and a negative electrode sheet stacked with other in that sequence. The composite solid electrolyte membrane is a continuous membrane structure and comprises a first part of composite solid electrolyte membrane and a second part of composite solid electrolyte membrane. The first part of composite solid electrolyte membrane is stacked and parallel with the at least one positive electrode sheet and the at least one negative electrode sheet. The second part of composite solid electrolyte membrane is located on a side surface of the lithium-ion battery.