Electrochemical Unit Mixture Layer Arc Plasma Coating
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Solution Overview
Problem
The production of electrochemical units is hindered by complex and costly vacuum film processes, and the use of arc plasma coating is limited by magnetism, making it difficult to incorporate magnetic materials and increasing production costs, which has hindered their widespread adoption in energy-saving applications like smart windows and secondary batteries.
Innovation Solution
An electrochemical unit with a mixture layer comprising 70-80 wt% transition metal oxides and 20-30 wt% alkali metal, formed using an arc plasma coating process, which simplifies the manufacturing process by eliminating the need for a separate electrolyte layer and reduces production costs, while allowing for the use of magnetic materials and enhancing ion conduction and redox reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vacuum film process is used to produce electrochemical units, then the quality and performance of the electrochemical unit are improved, but the production cost and process complexity are greatly increased
Solution Approach 1:
The patent changes the manufacturing parameters by switching from vacuum film deposition to arc plasma coating, which operates under different physical conditions (atmospheric pressure vs. vacuum). This parameter change simplifies the equipment requirements and reduces production complexity while maintaining acceptable product quality through controlled deposition parameters
Solution Approach 2:
The patent adopts a simpler, more cost-effective manufacturing approach using arc plasma coating equipment that is less expensive and more accessible than vacuum film deposition systems. The process uses readily available materials and equipment, making production more economical and suitable for widespread adoption
2Ease of manufacture
If arc plasma coating process is used, then production cost is reduced, but the use of magnetic materials as targets is limited due to susceptibility to magnetism
Solution Approach 1:
Instead of trying to overcome the magnetic interference in arc plasma coating, the patent inverts the approach by selecting non-magnetic transition metal materials (tantalum, nickel, tungsten) that are compatible with the arc plasma process. This material selection strategy allows the use of arc plasma coating's cost advantages while avoiding the magnetic interference issue entirely
3Ease of manufacture
If arc plasma coating process is used, then production cost is reduced, but the manufacturing process capability is limited
Solution Approach 1:
The patent optimizes the arc plasma coating process by carefully controlling deposition parameters such as coating thickness, deposition rate, and substrate temperature. These parameter adjustments enable the process to achieve sufficient manufacturing precision for electrochemical unit applications, balancing cost-effectiveness with adequate process capability
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 proposed solution reduces production costs and complexity, enhances ion conduction rates, and enables the use of magnetic materials, making the electrochemical units more viable for energy-saving applications such as smart windows and secondary batteries.
Implementation Method 1
disposing a first alkali metal at an anode of a first arc plasma coating process; disposing a transition metal alloy at a cathode of the first arc plasma coating process; forming a mixture layer on the substrate through the first arc plasma coating process
Implementation Method 2
enhancing ion conduction and redox reactions
Implementation Method 3
enhancing ion conduction and redox reactions
Data Source
AI summary
The present invention provides an electrochemical unit, a manufacturing method for the same and a use of the same as a component of batteries, and an electrochemical device including the same. The electrochemical unit includes a mixture layer and a transition metal oxide layer. The mixture layer includes an oxide made of a first transition metal, an oxide made of a second transition metal, and a first alkali metal. The transition metal oxide layer is disposed on one side of the mixture layer, where the transition metal oxide layer includes a third transition metal oxide.