Roll-to-Roll Gel Membrane Casting for Battery Interface Stability
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Solution Overview
Problem
Solid-state battery cells with solid electrolytes face challenges in high volume manufacturing due to rigid oxide electrolytes causing poor interfacial contact and reduced cyclability due to volumetric changes of electrode materials during cycling.
Innovation Solution
A gel membrane with high ionic conductivity and flexibility is introduced, fabricated using roll-to-roll hot casting of a gel precursor solution containing polyacrylonitrile, dual lithium salts, and solvents like ethylene carbonate and γ-butyrolactone, which improves electrode/electrolyte interfacial contact and cyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If rigid oxide electrolytes are used in solid-state batteries, then manufacturing complexity is reduced, but interfacial contact quality deteriorates and cyclability decreases due to volumetric changes of electrode materials
Solution Approach 1:
The patent changes the physical and chemical parameters of the electrolyte by using a gel membrane with specific composition (polymer matrix with liquid electrolyte) instead of rigid oxide. The gel membrane has controlled viscosity, flexibility, and ionic conductivity parameters that allow it to accommodate electrode volumetric changes while maintaining good interfacial contact, thus improving cyclability without significantly increasing manufacturing complexity
Solution Approach 2:
The invention uses a composite gel membrane structure combining polymer matrix (such as polyacrylonitrile) with liquid electrolyte components. This composite material provides both the mechanical flexibility needed to accommodate electrode expansion/contraction and the ionic conductivity required for battery operation, resolving the contradiction between manufacturing simplicity and cyclability
2Strength
If gel membrane solution with high polymer content is used, then membrane strength increases, but ionic conductivity decreases due to reduced liquid electrolyte content
Solution Approach 1:
The patent optimizes the concentration parameters of the gel membrane solution, specifically controlling the polymer content within 10-50 wt% and liquid electrolyte content within 50-90 wt%. This parameter optimization achieves a balance where the polymer provides sufficient mechanical strength while the liquid electrolyte maintains high ionic conductivity, resolving the contradiction between strength and ionic conductivity
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 gel membrane enhances power capability and cyclability of battery cells by providing favorable electrode/electrolyte interfacial contact and is scalable for continuous manufacturing.
Implementation Method 1
heating a gel membrane solution in a tank, wherein the gel membrane solution includes a polymer and a liquid electrolyte
Implementation Method 2
cooling the gel membrane layer on the first substrate
Data Source
AI summary
A method for manufacturing a gel membrane for a battery cell includes supplying a first substrate to a first roller; heating a gel membrane solution in a tank, wherein the gel membrane solution includes a polymer and a liquid electrolyte comprising one or more lithium salts; arranging a slot die within a predetermined distance of the first substrate located on the first roller; pumping the gel membrane solution into an inlet of the slot die; depositing a gel membrane layer from an outlet of the slot die onto the first substrate supported by the first roller; and cooling the gel membrane layer on the first substrate.