Ion-Exchange Electrode Coating to Simplify Battery Assembly
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Solution Overview
Problem
Existing battery systems require complex assembly of multiple components, leading to issues such as pinholes or leaks that can cause non-operation, leakage of caustic or acidic chemical agents, and damage to products, and there is a need for low-cost, high-energy density batteries with minimal assembly steps.
Innovation Solution
A process involving coating electrodes with n-mers to form ion exchange materials, which can be polymerized and crosslinked, creating an interpenetrating interface with the electrode, and optionally embedding or surrounding the electrode with ion exchange material, using techniques like dipping, spraying, or laminating, to enhance battery performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex assembly of multiple components (separators, casings, electrode materials) is used, then battery functionality is achieved, but manufacturing complexity and risk of pinholes/leaks increase
Solution Approach 1:
The patent combines multiple discrete components (electrode material, separator, and protective coating) into a single integrated structure. The ion exchange material is coated directly onto the electrode surface, merging the separator function and protective barrier function with the electrode itself, thereby reducing the number of discrete parts and assembly steps while improving reliability by eliminating interfaces between components where pinholes or leaks could occur
Solution Approach 2:
The ion exchange material coating serves multiple functions simultaneously: it acts as a separator to prevent direct contact between electrodes, provides a protective barrier against pinholes and leaks, and maintains ion transport functionality. This multi-functionality reduces the need for separate dedicated components, simplifying the overall battery structure while enhancing reliability
2Ease of manufacture
If traditional multi-component battery systems are used, then battery operation is achieved, but manufacturing cost and assembly steps increase
Solution Approach 1:
The invention merges the electrode material and separator into a single coated structure, reducing the quantity of discrete components. The ion exchange material is applied directly to the electrode surface through coating processes, eliminating the need for separate separator pieces and reducing assembly steps, thereby improving ease of manufacture
Solution Approach 2:
The patent extracts the separator function from its traditional discrete component form and integrates it directly onto the electrode surface through coating. This extraction and reintegration reduces the number of separate components that need to be handled and assembled, simplifying the manufacturing process
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 process results in batteries with improved cycle life, higher discharge voltage and capacity, lower internal resistance, and high-rate discharge capability, with enhanced electrical performance and reliability.
Implementation Method 1
The n-mer coated electrode is processed to polymerize the n-mer and form an ion exchange material that covers at least some of the electrode
Implementation Method 2
n-mer processing can include crosslinking or curing using at least one of heat, ultraviolet, or chemical agents
Implementation Method 3
n-mer processing can include crosslinking or curing using at least one of heat, ultraviolet, or chemical agents
Implementation Method 4
n-mer processing can include crosslinking or curing using at least one of heat, ultraviolet, or chemical agents
Implementation Method 5
ion transport can be enabled by a liquid alkaline electrolyte contacting the electrodes
Data Source
AI summary
A method of manufacturing a battery cell includes forming an electrode and coating the electrode with a n-mer solution. The n-mer coated electrode is treated by heat, ultraviolet, or cross linking agents to polymerize the n-mer and form an ion exchange material that covers at least some of the electrode.