Composite Solid Electrolyte Structure for Downhole Li-Ion Batteries
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Solution Overview
Problem
Conventional lithium-ion batteries fail to operate reliably at high temperatures and pressures encountered in downhole environments due to the limitations of liquid electrolytes, which pose safety risks and reduce energy density.
Innovation Solution
Development of a composite electrolyte structure for high-temperature, high-pressure lithium-ion batteries, formed by coating polymer electrolyte particles with oxides and using 3D printing and sintering techniques to create a solid electrolyte system that includes alternating layers of polymer and ceramic electrolytes, enhancing thermal stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid electrolytes are used in conventional lithium-ion batteries, then ease of manufacture and ion conductivity are improved, but safety and thermal stability deteriorate at high temperatures and pressures
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid to solid polymer form, fundamentally altering the parameters of viscosity, flammability, and thermal stability. This phase change enables the battery to operate safely at high temperatures and pressures while maintaining manufacturability through the coating and sintering processes described
Solution Approach 2:
The patent creates a composite electrolyte structure by coating polymer electrolyte particles with oxide materials. This composite approach combines the flexibility and ion conductivity of polymers with the thermal stability and safety of ceramic oxides, resolving the contradiction between ease of manufacture and safety at extreme conditions
2Reliability
If solid polymer electrolytes are used, then safety and thermal stability are improved, but ion conductivity and energy density deteriorate
Solution Approach 1:
The patent applies local quality by coating only the surface of polymer electrolyte particles with oxide materials rather than using bulk composite materials. This localized approach maintains the high ion conductivity of the polymer core while adding safety and thermal stability at the particle surfaces, thereby preserving energy density while improving safety
Solution Approach 2:
The patent utilizes the porous structure of polymer electrolyte particles to maintain high surface area to volume ratios. The coating process penetrates and adheres to this porous structure, creating a composite that retains the ion conductivity pathways within the polymer matrix while providing protective oxide layers, thus balancing safety improvements with energy density maintenance
3Reliability
If oxide coating is applied to polymer electrolyte particles, then thermal stability and safety are improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical coating processes with a chemical vapor deposition or solution-based coating method. The oxide coating is applied through chemical reactions or solution immersion rather than mechanical layering, simplifying the manufacturing process while achieving uniform thermal protection on polymer electrolyte particles
Solution Approach 2:
The patent optimizes coating parameters such as coating thickness, oxide composition, and deposition temperature to achieve the desired thermal stability with minimal processing steps. By carefully controlling these parameters, the manufacturing complexity is kept manageable while still achieving the necessary thermal stability for high-temperature operation
4Adaptability or versatility
If 3D printing and sintering techniques are used to create composite electrolyte structure, then customization and performance optimization are improved, but manufacturing time and energy consumption increase
Solution Approach 1:
The patent applies preliminary action by pre-coating polymer electrolyte particles with oxide materials before the 3D printing process. This pre-preparation of coated particles allows for faster printing speeds and reduces the overall manufacturing time, as the coating step is performed in advance rather than during or after printing
Solution Approach 2:
The patent optimizes sintering parameters including temperature, pressure, and duration to achieve rapid bonding of coated particles into the final electrolyte structure. By carefully controlling these parameters, the sintering process is accelerated while still achieving the desired structural integrity and ion conductivity, thereby reducing manufacturing time and energy consumption
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 solution enables lithium-ion batteries to operate safely and efficiently at extreme conditions, eliminating flammability and corrosion risks, simplifying battery design, and potentially increasing energy density beyond conventional limits.
Implementation Method 1
coating polymer electrolyte particles with an oxide to make coated polymer electrolyte particles... enhancing thermal stability and safety
Implementation Method 2
coating polymer electrolyte particles with an oxide... eliminating flammability and corrosion risks
Implementation Method 3
printing a polymer electrolyte preform in a binder jet printer from the coated polymer electrolyte particles... polymer electrolyte preforms that are bonded into the composite electrolyte structure
Implementation Method 4
using 3D printing and sintering techniques to create a solid electrolyte structure... polymer electrolyte preforms that are bonded into the composite electrolyte structure
Data Source
AI summary
A system and a method for forming a composite electrolyte structure are provided. An exemplary composite electrolyte structure includes, at least in part, polymer electrolyte preforms that are bonded into the composite electrolyte structure.