Internal Polymeric Battery Support for Swelling and Delamination
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Solution Overview
Problem
Lithium-based batteries experience volumetric changes due to gas formation, leading to electrode separation and delamination, which degrades ion transfer paths and results in cell failure, with conventional metal-based compressive structures increasing weight and cost while reducing battery performance.
Innovation Solution
A polymeric support system is used as a compressive structure within the battery, comprising a continuous network of polymers that provides mechanical strength and anchors to the electrodes, potentially reducing overall weight and cost by replacing metal components with lighter, ionically conductive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal-based compressive structures are used to prevent electrode separation, then mechanical strength is improved, but weight increases substantially
Solution Approach 1:
The patent changes the material parameter from metal to polymer, fundamentally altering the density and mechanical properties. The polymer support structure maintains necessary mechanical strength while reducing density from typical metal values (e.g., aluminum 2.7 g/cm³, stainless steel 7.9 g/cm³) to polymer ranges (0.9-2.0 g/cm³), directly resolving the weight-strength contradiction
Solution Approach 2:
The patent employs composite material strategies by combining polymer matrices with reinforcing elements such as fibers or fillers to achieve the necessary mechanical strength without metal. The composite structure allows tailoring of mechanical properties to meet compression requirements while maintaining low weight
2Strength
If metal-based compressive structures are used to prevent electrode separation, then mechanical strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive metal components with cheaper polymer alternatives. The polymer support structure can be manufactured at lower material costs and potentially eliminated after serving its protective function during critical phases, reducing overall manufacturing expenditure while maintaining necessary mechanical support
3Reliability
If metal-based compressive structures are used to prevent electrode separation, then electrode delamination is prevented, but battery performance decreases
Solution Approach 1:
The patent substitutes the mechanical metal compressive structure with a polymer-based system that may offer additional functional benefits beyond pure mechanical support, such as ion conductivity or electrochemical compatibility, thereby maintaining electrode stability while potentially improving overall battery performance metrics
4Weight of moving object
If polymer support system is used instead of metal structure, then weight is reduced, but mechanical strength may be compromised
Solution Approach 1:
The patent employs composite material strategies by combining polymer matrices with reinforcing elements such as fibers or fillers to achieve the necessary mechanical strength without metal. The composite structure allows tailoring of mechanical properties to meet compression requirements while maintaining low weight
Solution Approach 2:
The patent optimizes polymer parameters including crosslinking density, molecular weight, and compositional ratios to enhance mechanical strength. By adjusting these parameters, the polymer support structure achieves sufficient compressive and tensile strength to prevent electrode delamination while maintaining weight advantages over metal
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 polymeric support system enhances mechanical strength, reduces weight and volume, and improves battery performance by maintaining electrochemical conditions without adding weight, enabling more efficient energy use and extended range in applications like electric vehicles.
Implementation Method 1
The polymeric support system may be used to provide mechanical strength to components of an electrochemical cell
Implementation Method 2
batteries, particularly lithium-based batteries, are known to experience volumetric change over the course of operational lifetime
Implementation Method 3
ion transfer paths through the electrochemical cell are degraded
Implementation Method 4
either or (preferably) both the anode, the anode current collector(s), the cathode, and the cathode current collector(s) may be perforated, may be porous, may be configured as a mesh, expanded metal, or other configuration that would be appreciated by a person having ordinary skill in the art upon reading the present disclosure as suitable for use as an anchor or other physical coupling between the polymeric support system and components of the electrochemical cell
Data Source
AI summary
Electrochemical cells and batteries including a polymeric support system in lieu of a conventional, metal-based structures. The polymer support system provides mechanical strength and mechanical flexibility to the electrochemical cells in a manner that is advantageously greater than what is provided by conventional structures, in spite of the fact that the polymer support system contributes far less to the overall weight of the electrochemical cells. The polymer support system may be present in an interior volume of an electrochemical cell, e.g., in the form of a continuous polymeric network penetrating various components of the electrochemical cell. The penetrating structures may include the anode and cathode current collectors, and any/all components therebetween. Additionally or alternatively, the polymer support system may include various forms of external support structures, chemical anchors, coatings and/or casings of the electrochemical cell. Additional advantageous characteristics include improved recyclability and increased longevity of the electrochemical cells.