Ion-Exchange Battery Cell Structure for Leak-Resistant Thin Cells
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery systems require complex assembly and are prone to issues like pinholes, leaks, and chemical agent leakage, which can lead to non-operation and damage, especially in applications like portable devices and electric vehicles, where low-cost, high-energy-density batteries with minimal assembly steps are needed.
Innovation Solution
A battery cell design featuring electrodes made from metal foils or meshes with an ion exchange material acting as an electrolyte, positioned between the electrodes, which can be coated with n-mer solutions to form a polymerized ion exchange material, providing ionic conductivity and reducing the need for separate separators and casings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery systems use multiple discrete components (separators, casings, electrolytes), then reliability is improved by having dedicated functional elements, but device complexity increases and manufacturing becomes more costly
Solution Approach 1:
The patent combines the separator and electrolyte functions into a single integrated component - an ion-exchange membrane that provides both physical separation and ionic conductivity. This merging eliminates the need for separate separator and electrolyte components, reducing assembly complexity while maintaining the functional reliability of having both separation and ion transport capabilities.
Solution Approach 2:
The ion-exchange membrane serves multiple functions simultaneously: it acts as a separator to prevent direct contact between electrodes, provides the electrolyte medium for ion transport, and offers mechanical support structure. This multi-functionality reduces the total number of components needed while ensuring reliable performance of each function.
2Reliability
If battery systems use traditional multi-component assembly, then functional performance is maintained, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
By merging the separator and electrolyte into a single ion-exchange membrane component, the manufacturing process is simplified from assembling multiple discrete parts to installing one integrated component. This reduces assembly steps, decreases manufacturing time, and improves production efficiency while maintaining the performance benefits of having both separation and ion transport functions.
Solution Approach 2:
The invention segments out the ion-exchange membrane as a pre-fabricated integrated unit that combines separator and electrolyte functions, allowing it to be manufactured separately and then installed as a single component. This segmentation of the manufacturing process enables specialized production of the membrane while simplifying the final battery assembly operation.
3Reliability
If battery cells use conventional designs with separate separators and casings, then functional separation is achieved, but the battery thickness and overall size increase
Solution Approach 1:
The ion-exchange membrane merges the separator and electrolyte into a single thin-film component that provides both electrode separation and ionic conduction in one layer. This integration eliminates the need for separate separator and electrolyte layers, significantly reducing the overall battery thickness while maintaining effective electrode separation.
Solution Approach 2:
The ion-exchange membrane is implemented as a thin-film structure that provides the necessary separation and ion transport functions in a minimal thickness. This thin-film approach allows the battery to achieve reduced overall dimensions while maintaining the functional integrity of electrode separation and electrolyte performance.
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 solution results in battery cells with improved cycle life, higher discharge voltage, lower internal resistance, and high-rate discharge capability, along with a thin form factor, making them suitable for various applications including flexible and integrated electronic circuits.
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
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
Data Source
AI summary
A battery cell includes a first electrode formed from at least one of a metal foil, a metal mesh or a metal layer on a substrate. A second electrode can be formed from at least partially oxidized material in a form of at least one of a metal foil, a metal layer on a substrate, a metal mesh, or a battery electrode that includes plurality of particles on current collector. A layer of an ion exchange material can be positioned between the first and second electrodes, with the ion exchange material capable of acting as an electrolyte in some embodiments.