Laminate Electrochemical Cell With Polymer-Ceramic Electrolyte Layers
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Solution Overview
Problem
Lithium-ion batteries with liquid electrolytes face safety concerns due to thermal runaway and leakage, while solid-state batteries offer higher energy density but are costly and require new manufacturing equipment, limiting their mainstream adoption.
Innovation Solution
A laminate electrochemical cell design featuring a cathode layer, a polymer electrolyte layer coating the anode, and a ceramic layer between them, using standard manufacturing equipment and processes, which reduces thermal runaway risk and increases energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid electrolyte is used in lithium-ion batteries, then ease of manufacture is improved, but safety deteriorates due to thermal runaway and leakage risks
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid to solid polymer, fundamentally altering the safety characteristics while maintaining manufacturability through conventional lamination processes
Solution Approach 2:
The patent employs a composite structure with multiple polymer electrolyte layers having different compositions and properties, combining the benefits of each layer to achieve both safety and manufacturability
2Quantity of substance
If solid-state electrochemical cells are used, then energy density is improved, but manufacturing cost deteriorates due to new equipment and processes required
Solution Approach 1:
The patent modifies the electrolyte from liquid to solid polymer form, enabling higher energy density while using existing manufacturing equipment and processes
Solution Approach 2:
The patent designs the solid polymer electrolyte to serve multiple functions: as an ionic conductor, as a separator, and as a structural component, eliminating the need for separate manufacturing steps required by traditional solid-state batteries
3Quantity of substance
If solid-state electrochemical cells are used, then energy density is improved, but device complexity deteriorates due to new manufacturing equipment and processes
Solution Approach 1:
The patent transitions from liquid to solid polymer electrolyte, achieving higher energy density while simplifying the manufacturing system by using existing equipment
Solution Approach 2:
The patent divides the electrolyte into multiple discrete polymer layers with different compositions, each performing specific functions, which simplifies the overall manufacturing process compared to traditional solid-state battery approaches
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 laminate electrochemical cell design enhances safety by reducing thermal runaway risk and achieves higher energy density compared to conventional lithium-ion batteries, while being more cost-effective and easier to manufacture than solid-state cells.
Implementation Method 1
a polymer electrolyte layer arranged between the cathode layer and the anode layer
Implementation Method 2
a ceramic layer arranged between the polymer electrolyte layer and the cathode layer
Data Source
AI summary
Described herein is a laminate electrochemical cell including a cathode layer, an anode layer, a polymer electrolyte layer, and a ceramic layer. The polymer electrode layer is arranged between the cathode layer and the anode layer and coats at least a portion of the anode layer. The ceramic layer is arranged between the polymer electrolyte layer and the cathode layer. The ceramic layer and the polymer electrolyte layer have different compositions. Also described herein are methods of manufacturing the laminate electrochemical cell, battery stacks including a plurality of said laminate electrochemical cells, and electrically-powered devices including the electrochemical cell or battery stack.