Ion-Exchange Battery Cell Structure for Leak-Resistant Electrode Assembly
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Solution Overview
Problem
Existing battery systems require complex assembly of multiple components, are prone to pinholes or leaks, and lack high energy density and reliability, making them unsuitable for portable devices and IoT applications.
Innovation Solution
A battery cell design featuring a first electrode made from metal foil, metal layer, or metal mesh, and a second electrode formed from at least partially oxidized material, with an ion exchange material acting as both electrolyte and separator, reducing assembly complexity and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional battery systems use multiple discrete components (electrode material, separators, collectors, casings), then assembly complexity increases, but manufacturing precision and reliability improve
Solution Approach 1:
The patent combines multiple discrete battery components (separator, electrolyte, electrode material) into a single integrated structure where the separator is coated with ion-exchange material that serves as both separator and electrolyte reservoir, reducing assembly steps while maintaining reliability through the integrated design
Solution Approach 2:
The ion-exchange material coating on the separator performs multiple functions simultaneously: it acts as the separator itself, serves as an electrolyte reservoir, and provides ionic conductivity, eliminating the need for separate electrolyte filling steps and reducing potential failure points
2Ease of manufacture
If traditional battery systems use multiple discrete components, then ease of manufacture improves, but the risk of pinholes and leaks increases
Solution Approach 1:
By combining the electrolyte reservoir function directly into the separator structure through ion-exchange material coating, the patent eliminates separate electrolyte compartments and sealing requirements, reducing manufacturing steps while eliminating pinhole and leak risks associated with traditional electrolyte containment
3Quantity of substance
If battery systems use conventional designs, then manufacturing cost decreases, but energy density and cycle life improve with new designs
Solution Approach 1:
The integration of separator and electrolyte functions into a single coated structure reduces the overall volume required for battery components, allowing higher energy density while the simplified assembly process offsets the complexity of the new structure
4Productivity
If battery systems use minimal assembly steps, then productivity increases, but reliability may worsen
Solution Approach 1:
The patent merges separator and electrolyte into a single integrated component that can be applied in one coating step, dramatically increasing assembly speed while the integrated design eliminates multiple potential failure points (seals, connections) thereby improving reliability
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 proposed battery cell design achieves higher energy density, improved cycle life, lower internal resistance, and high-rate discharge capability, while simplifying assembly and reducing the risk of leaks and electrical shorts.
Implementation Method 1
A layer of an ion exchange material is positioned between the first and second electrodes, with the ion exchange material having sufficient ionic conductivity to act as an electrolyte
Implementation Method 2
a second electrode formed from at least partially oxidized material
Implementation Method 3
a battery cell includes a first electrode formed from at least one of a metal foil, metal layer on a substrate and a metal mesh and a second electrode formed from at least partially oxidized material
Data Source
AI summary
Systems and methods for space configurable battery structures for electrical assemblies incorporating ion exchange materials are described. One method to construct such a battery includes preparing a battery casing for a rechargeable battery. The preparing may further include placing one or more electrode materials into the casing. A monomer or a functionalized n-mer may be prepared for polymerization. The monomer or the functionalized n-mer may be polymerized to form an ion exchange material, which is then then cross-linked. The ion exchange material may be arranged to define an interpenetrating surface with at least a portion of at least one of the electrodes.