Laminated Electric Core for Thin Film Battery
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Solution Overview
Problem
Conventional lithium-ion batteries face challenges in achieving a cost-effective, high-energy-density, and long-lasting design with improved gas and moisture resistance, particularly in portable electronic devices where size and weight reduction are critical, and existing substrates like copper clad laminates increase manufacturing complexity and weight.
Innovation Solution
A laminated electric core for lithium-ion batteries is developed, comprising a first and second current collecting substrate with electrode active material layers, a separator, and an adhesive layer that creates an intimate interface to prevent delamination, allowing for a bendable and robust structure with enhanced gas and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper clad laminate (CCL) substrates are used for current collectors, then electrical connection and structural support are achieved, but manufacturing cost and device weight increase
Solution Approach 1:
The patent replaces expensive CCL substrates with inexpensive metal foils (aluminum or copper) that serve as current collectors. These metal foils are thin, lightweight, and sufficient for the application, eliminating the need for heavy and costly laminate structures while maintaining electrical conductivity and structural support functions.
Solution Approach 2:
The invention extracts and removes the non-essential heavy components (circuit board layers, fiberglass reinforcement) from the current collector structure, retaining only the essential metal foil layer that provides electrical conductivity. This simplification reduces weight while maintaining the core functional requirements.
2Duration of action of moving object
If conventional battery structures are used, then basic electrochemical function is achieved, but gas generation occurs at high temperature reducing battery life span
Solution Approach 1:
The patent employs an aluminum foil current collector that forms a protective oxide layer, creating a stable and inert environment that prevents harmful chemical reactions and gas generation at high temperatures. This inert barrier protects the battery components from degradation and extends life span.
Solution Approach 2:
The invention uses composite structures where metal foils are combined with thin adhesive layers and electrode materials to create a multi-layer system that provides both structural integrity and resistance to high-temperature gas generation, improving overall battery stability and longevity.
3Weight of moving object
If thin film battery structure is implemented, then size and weight reduction are achieved, but structural robustness and resistance to delamination are compromised
Solution Approach 1:
The patent utilizes thin metal foil current collectors that provide both flexibility for size reduction and sufficient mechanical strength when properly designed. The thin films are engineered to maintain structural robustness while enabling the lightweight, compact form factor required for portable devices.
Solution Approach 2:
The invention creates composite structures by laminating thin metal foils with adhesive layers and electrode materials, forming a multi-layer system where each layer contributes specific properties. This composite approach enhances overall structural robustness and prevents delamination while maintaining the lightweight advantage of thin films.
4Quantity of substance
If complex manufacturing processes are used to achieve high energy density, then battery capacity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent adopts inexpensive metal foil current collectors that simplify manufacturing processes and reduce cost, while still achieving high energy density through optimized electrode design and material selection. The simplicity of working with metal foils versus complex laminates reduces manufacturing complexity.
Solution Approach 2:
The invention optimizes parameters such as metal foil thickness, adhesive layer composition, and electrode material loading to achieve high energy density without requiring complex manufacturing processes. By carefully controlling these parameters, the patent attains high capacity with simplified production methods.
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 a cost-effective, high-capacity, and long-lasting lithium-ion battery with improved cycle performance and resistance to gas and moisture, enabling the batteries to maintain performance in portable electronic devices while reducing manufacturing complexity and weight.
Implementation Method 1
an adhesive layer, disposed between the first electrode active material layer and the separator, to create an intimate interface between the first electrode active material layer and the separator
Data Source
AI summary
A laminated electric core for a lithium-ion battery includes a first current collecting substrate; a first electrode active material layer coated on an inner surface of the first current collecting substrate; a second current collecting substrate; a second electrode active material layer coated on an inner surface of the second current collecting substrate; a separator sandwiched between the first electrode active material layer and the second electrode active material layer, wherein an electrolyte is retained at least in the separator; an adhesive layer between the first electrode active material layer and the separator; a first sealant layer on the inner surface of the first current collecting substrate along peripheral edges of the first electrode active material layer; and a second sealant layer on the inner surface of the second current collecting substrate along peripheral edges of the second electrode active material layer.