Flexible Battery Electrolyte Impregnation for Repeated Bending
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Solution Overview
Problem
Existing flexible batteries face issues with incomplete electrolyte impregnation of electrode assemblies, leading to surface spots and limitations in design flexibility due to the use of metal cans, which restricts their application in thin, lightweight, and high-capacity mobile electronic devices.
Innovation Solution
A manufacturing method involving an injection step, an impregnation step using a pressure increasing/decreasing process to ensure complete electrolyte impregnation of the electrode assembly within a flexible exterior material, and a sealing step to prevent physical deterioration upon bending, with specific pressure cycles and maintenance times to minimize spot occurrence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pressure increasing/decreasing process is performed during impregnation, then complete electrolyte impregnation is achieved without surface spots, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies periodic pressure increasing/decreasing cycles during the impregnation process. The pressure is repeatedly increased to inject electrolyte into the electrode assembly and then decreased to allow complete penetration, creating a cyclic impregnation action that ensures thorough electrolyte distribution without leaving surface spots.
Solution Approach 2:
The pressure differential created during the impregnation process naturally drives the electrolyte into the electrode assembly without requiring additional mechanical intervention. The system uses its own pressure variations to achieve complete impregnation, eliminating the need for complex external impregnation equipment.
2Adaptability or versatility
If pouch-type batteries are used instead of metal cans, then design flexibility and energy density are improved, but incomplete electrolyte impregnation occurs leading to surface spots
Solution Approach 1:
The periodic pressure increasing/decreasing process ensures that the electrolyte is progressively pushed into the porous structure of the electrode assembly in cycles, allowing complete penetration throughout the pouch-type battery structure, which has different fluid dynamics compared to rigid metal cans.
Solution Approach 2:
The patent changes the pressure parameter during impregnation, varying it between increased and decreased states to control the flow of electrolyte into the electrode assembly. This parameter modulation ensures complete impregnation while adapting to the flexible pouch structure.
3Adaptability or versatility
If repeated bending occurs during flexible battery usage, then flexibility is maintained, but physical characteristics deteriorate
Solution Approach 1:
The patent performs complete electrolyte impregnation before the battery is put into service through repeated bending. By ensuring thorough electrolyte penetration into all electrode structures in advance, the battery is prepared to maintain its physical characteristics even when subjected to repeated bending during usage.
Solution Approach 2:
The complete impregnation process acts as a preparatory measure that cushions against future deterioration. By ensuring all electrode surfaces are fully saturated with electrolyte before flexing, the patent prevents dry spots and uneven performance that would otherwise occur during repeated bending.
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 achieves complete electrolyte impregnation without surface spots and maintains the physical characteristics of flexible batteries even after repeated bending, enhancing their suitability for flexible mobile electronic devices.
Implementation Method 1
an impregnation step of impregnating the electrode assembly with the electrolyte through a pressure difference inside the exterior material
Data Source
AI summary
A manufacturing method for a flexible battery including injecting an electrolyte into an opening of an exterior material accommodating an electrode assembly contained therein and impregnating the electrode assembly with the electrolyte through a pressure difference inside the exterior material; and a sealing step of sealing the opening. Because the electrode assembly provided in the battery can be completely impregnated with an electrolyte, no spot occurs on the surface of a negative electrode filled with the electrolyte. In addition, the flexible battery can prevent or minimize deterioration of physical characteristics that the battery is required to exhibit, even if repeated bending occurs.