Electrode Assembly End-Surface Insulation for Carrier Ion Replenishment
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Solution Overview
Problem
Existing secondary batteries suffer from irreversible capacity loss due to the formation of a solid electrolyte interphase (SEI) during charging, leading to reduced capacity and efficiency, with existing methods failing to effectively replenish lost carrier ions.
Innovation Solution
A method of manufacturing an electrode assembly with a porous electrically insulating material applied using a stencil to cover the vertical end surfaces of unit cells, facilitating the transfer of carrier ions and replenishing those lost during SEI formation, thereby enhancing ion transfer and maintaining battery performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secondary battery undergoes charging and discharging cycles, then energy storage and release function is achieved, but carrier ions are irreversibly lost to SEI formation and electrode degradation
Solution Approach 1:
The patent applies the discarding and recovering principle by introducing a replenishment electrode containing carrier ions that can be transferred to the primary electrodes. During charging cycles, carrier ions are recovered from the replenishment electrode and transferred to the primary electrodes, compensating for the irreversible losses due to SEI formation and degradation. This restores the battery's capacity and extends cycle life without requiring complete battery replacement.
Solution Approach 2:
The patent implements self-service through an automated carrier ion replenishment system. The battery performs its own maintenance by automatically transferring carrier ions from the replenishment electrode to the primary electrodes during regular charging cycles, eliminating the need for external intervention or specialized maintenance procedures. The system monitors and replenishes carrier ions as needed, allowing the battery to maintain optimal performance autonomously.
2Reliability
If the electrode assembly structure is designed to accommodate replenishment electrodes, then carrier ion replenishment is enabled, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating the replenishment electrode into the existing electrode assembly structure. The replenishment electrode is positioned within the same housing and electrolyte environment as the primary electrodes, sharing common structural elements such as the housing, separator, and electrolyte. This combined design enables carrier ion replenishment while avoiding the need for separate, complex replenishment systems.
Solution Approach 2:
The patent implements multi-functionality by designing the replenishment electrode to serve multiple purposes: it acts as an additional carrier ion reservoir, a structural component of the electrode assembly, and a self-replenishing mechanism. The same charging infrastructure used for normal battery operation is also utilized to transfer carrier ions from the replenishment electrode to the primary electrodes, eliminating the need for specialized equipment.
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 method increases the cycle life, energy density, and discharge rate of secondary batteries by effectively replenishing lost carrier ions, improving overall battery performance.
Implementation Method 1
the porous electrically insulating material... facilitating the transfer of carrier ions
Data Source
AI summary
A method for manufacturing a structure comprising and electrode assembly having a porous electrically insulating material, and first and second endplates, is provided. The electrode assembly comprises a population of unit cells stacked in series in a stacking direction, opposing first and second longitudinal end surfaces separated along the stacking direction. First and second endplates are separated in the stacking direction and overlie the first and second longitudinal end surfaces. According to embodiments of the structure, (i) each unit cell comprises an electrode structure, a counter-electrode structure, and an electrically insulating separator between the electrode and counter-electrode structures, (ii) the electrode structures, counter-electrode structures and electrically insulating separators within each unit cell have opposing first and second vertical end surfaces separated in a vertical direction, and (iii) the vertical direction is orthogonal to the stacking direction. The method comprises providing a porous electrically insulating material to the electrode assembly using a stencil.