Non-Aqueous Electrolyte Blends for Thick-Electrode Li-Ion Cells

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Solution Overview

Problem

Existing lithium ion batteries face challenges in achieving higher energy density and discharge rates, particularly as electrodes become thicker, necessitating improved electrolyte formulations to enhance electrochemical performance and capacity retention.

Innovation Solution

The development of a non-aqueous electrolyte solvent blend comprising ethylene carbonate (EC) and additional solvents like ethyl methyl carbonate (EMC) or propylene carbonate (PC) in specific volume ratios, along with lithium salts and optional additives, to form a stable solid electrolyte interphase (SEI) layer, improving discharge rates and capacity retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If electrodes are made thicker to increase energy density, then energy storage capacity is improved, but discharge rate capability deteriorates

Engineering Contradiction:
Improveenergy storage capacityVSAvoiddischarge rate
Core Design Contradiction:
Quantity of substanceVSSpeed

Solution Approach 1:

The patent changes the chemical composition parameters of the electrolyte by introducing a boronic acid derivative additive in specific concentrations (0.1-5 wt% relative to lithium salt). This parameter change modifies the electrolyte's interaction with the electrode surface, enabling improved discharge rates even with thicker electrodes by optimizing ion transport kinetics at the electrode-electrolyte interface.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite electrolyte system combining lithium salt, cyclic carbonate solvents (EC, PC), chain carbonate solvents (DMC, DEC, EMC), and boronic acid derivative additive. This composite formulation synergistically combines the high dielectric constant of cyclic carbonates, the low viscosity of chain carbonates, and the surface-modifying properties of the boronic acid additive, achieving both high energy density and high discharge rate capability.

Inventive Principle:
Principle #40Composite materials

2Ease of manufacture

If conventional electrolyte formulations are used with thicker electrodes, then manufacturing simplicity is maintained, but capacity retention deteriorates

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidcapacity retention
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent modifies the electrolyte composition by adding boronic acid derivative at controlled concentrations (0.1-5 wt% relative to lithium salt). This parameter adjustment improves capacity retention in thick electrodes by forming stable SEI layers that prevent electrode degradation during cycling, while maintaining compatibility with existing manufacturing processes.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The boronic acid derivative acts as an intermediary substance that mediates between the electrolyte and electrode surfaces. It forms protective interfacial layers that improve capacity retention and cycling stability, while the overall electrolyte formulation and application process remain compatible with conventional battery manufacturing methods.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Power

If electrolyte composition is optimized for high discharge rates, then power capability is improved, but energy density deteriorates

Engineering Contradiction:
Improvepower capabilityVSAvoidenergy density
Core Design Contradiction:
PowerVSQuantity of substance

Solution Approach 1:

The patent employs a composite electrolyte formulation that integrates multiple solvent types (cyclic and chain carbonates) with a boronic acid derivative additive. The cyclic carbonates (EC, PC) provide high dielectric constant for lithium salt dissolution, chain carbonates (DMC, DEC, EMC) provide low viscosity for fast ion transport, and the boronic acid additive provides surface stabilization. This composite approach achieves both high power capability and high energy density simultaneously.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The boronic acid derivative additive provides localized quality improvement at the electrode-electrolyte interface while the bulk electrolyte maintains properties optimized for energy density. The additive concentration (0.1-5 wt%) is sufficient to modify interfacial properties for high power capability without significantly affecting the bulk electrolyte's energy storage characteristics.

Inventive Principle:
Principle #3Local quality

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 improved electrolyte formulations enhance discharge rate capability, especially at higher C-rates, and provide better capacity retention and cycling performance, suitable for high-energy, high-power applications such as electric vehicle propulsion.

Implementation Method 1

The development of a non-aqueous electrolyte solvent blend comprising ethylene carbonate (EC) and additional solvents like ethyl methyl carbonate (EMC) or propylene carbonate (PC) in specific volume ratios, along with lithium salts and optional additives, to form a stable solid electrolyte interphase (SEI) layer

Methodology Applied
Scientific EffectSolid electrolyte interphase (SEI) formation:

Data Source

PatentUS12500272B2Non-aqueous solvent electrolyte formulations for energy storage devices
Publication Date: 2025.12.16 TESLA INC
  • US12500272B2 patent drawing
  • US12500272B2 patent drawing
  • US12500272B2 patent drawing

AI summary

Provided herein are improved electrolyte formulations. The improved performance may be realized as improved discharge rate cycling, improved capacity, improved Coulombic efficiency, or improved capacity upon cycling.