Fiber-Reinforced Electrode Substrate for Short-Circuit Resistance
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Solution Overview
Problem
Rechargeable lithium batteries face challenges in achieving high energy density and mechanical strength, particularly in preventing short-circuits due to foreign object penetration.
Innovation Solution
The electrode substrate includes a support layer made of a polymer resin matrix impregnated fibers, with a metal layer on at least one surface, enhancing mechanical strength and preventing short-circuits through high-temperature shrinkage of the dielectric material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional substrate structure is used, then the battery can be manufactured with standard processes, but the mechanical strength is insufficient and short-circuit risk increases
Solution Approach 1:
The substrate is constructed as a composite material consisting of a polymer resin matrix combined with inorganic filler particles. This composite structure provides both mechanical strength and thermal stability, preventing short-circuits while maintaining manufacturability. The inorganic filler particles dispersed in the polymer matrix create a robust structure that resists deformation and penetration.
2Strength
If the substrate thickness is increased to improve mechanical strength, then strength improves, but the energy density decreases
Solution Approach 1:
The substrate thickness is optimized to a specific range (3 μm to 10 μm) to achieve the desired mechanical strength without excessive thickness. Within this optimized parameter range, the substrate provides sufficient strength to prevent short-circuits while minimizing the volume occupied by non-active materials, thereby maintaining high energy density.
Solution Approach 2:
The composite structure with inorganic filler particles enhances the mechanical strength per unit thickness, allowing the substrate to achieve required strength at thinner dimensions. This enables high energy density while maintaining adequate mechanical protection against short-circuits.
3Strength
If a fiber-reinforced polymer structure is used, then mechanical strength improves, but the manufacturing complexity increases
Solution Approach 1:
Instead of using complex fiber-reinforced structures throughout the entire substrate, inorganic filler particles are selectively incorporated into the polymer matrix. This local reinforcement approach provides enhanced mechanical strength where needed while keeping the overall substrate structure simple and compatible with standard manufacturing processes.
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 substrate design improves mechanical strength and reduces the risk of short-circuits, enabling higher energy density and processability while maintaining flexibility.
Implementation Method 1
preventing short-circuits through high-temperature shrinkage of the dielectric material
Data Source
AI summary
Disclosed are electrode substrates for rechargeable lithium batteries, and rechargeable lithium batteries including the electrode substrates. The electrode substrate for a rechargeable lithium battery includes a support layer that includes a polymer resin matrix and a fiber, and a metal layer on at least one surface of the support layer. An average cross-sectional diameter of the fiber is in a range of about 0.1 μm to about 10 μm.