Ion-Exchange Battery Electrode Structure With Integrated Electrolyte
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Solution Overview
Problem
Existing battery systems require complex assembly of multiple components, are prone to pinholes or leaks, and often necessitate external containers, leading to potential chemical leakage and damage.
Innovation Solution
A battery cell design featuring electrodes coated with an ion exchange material that acts as an electrolyte, allowing for simplified assembly and integration into devices like printed circuit boards, with electrodes optionally embedded in or surrounded by the ion exchange material for enhanced rigidity and reduced shorting risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery systems use multiple discrete components (electrode material, separators, collectors, casings), then assembly complexity increases, but manufacturing precision and reliability decrease due to pinholes or leaks in separators or casings
Solution Approach 1:
The patent combines multiple discrete battery components (separator, electrolyte, electrode coatings) into a single integrated ion-exchange membrane layer. This merging eliminates the need for separate assembly steps and reduces the number of potential failure points from pinholes or leaks in multiple components to a single continuous barrier layer, thereby improving reliability while reducing assembly complexity.
Solution Approach 2:
The ion-exchange membrane performs multiple functions simultaneously: it acts as a separator to prevent direct contact between electrodes, provides an electrolyte medium for ion transport through its ion-conductive properties, and serves as a protective casing layer. This multi-functionality eliminates the need for separate discrete components, simplifying assembly while maintaining high reliability.
2Manufacturing precision
If ion exchange material is applied as a coating on electrodes, then manufacturing precision improves with intimate contact, but the complexity of coating and polymerization processes increases
Solution Approach 1:
The ion-exchange material is applied as a coating that self-adheres to the electrode surface through electrostatic or chemical attraction, eliminating the need for complex bonding or sealing processes. The material's inherent properties enable it to conform to the electrode geometry and maintain intimate contact without additional manufacturing steps, improving precision while keeping the process simple.
Solution Approach 2:
The patent utilizes changes in the physical or chemical state of the ion-exchange material during application—for example, transitioning from a soluble precursor to an insoluble polymerized form—to achieve permanent bonding to the electrode. This parameter change enables the coating to adhere strongly and maintain precise contact without requiring complex external bonding processes.
3Strength
If electrodes are embedded in or surrounded by ion exchange material, then rigidity and shorting prevention improve, but the volume of the battery cell increases
Solution Approach 1:
The ion-exchange membrane is applied as a thin film or coating on the electrode surface rather than as a thick surrounding structure. This thin film provides sufficient mechanical support and rigidity to prevent electrode deformation and shorting while occupying minimal additional volume, thus improving strength without significantly increasing battery cell volume.
Solution Approach 2:
The ion-exchange material forms a continuous protective and structural layer around or on the electrodes, providing ongoing mechanical support and shorting prevention throughout battery operation. This continuous structure maximizes strength-to-volume ratio by eliminating gaps or discontinuities that would require additional material for equivalent protection.
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 design achieves high energy density, improved cycle life, lower internal resistance, and flexible form factors, reducing the need for external packaging and enhancing electrical performance.
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
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.