Lithium Metal Battery Separator Layout to Suppress Short Circuits

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Solution Overview

Problem

Existing lithium metal secondary batteries face issues with abnormal lithium precipitation and short circuits due to improper material selection and contact between conductive layers, particularly when using long continuous separators.

Innovation Solution

A lithium metal secondary battery design featuring a separator with a zigzag configuration and a two-layer structure comprising an electrically conductive layer in contact with the negative electrode and an insulating layer opposing the positive electrode, along with a fixing mechanism to secure insulation between the electrode laminate and the laminate film.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an electrically conductive layer is added to the separator to suppress lithium metal abnormal precipitation, then lithium dissolution precipitation is improved, but the risk of short circuit due to contact between the conductive layer and positive electrode or aluminum layer increases

Engineering Contradiction:
Improvelithium dissolution precipitationVSAvoidshort circuit risk
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The separator is divided into multiple layers: a base separator layer and an electrically conductive layer. This segmentation allows the conductive layer to suppress lithium abnormal precipitation while the base separator provides insulation to prevent short circuits between the conductive layer and positive electrode or aluminum layer.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The base separator layer acts as an intermediary between the electrically conductive layer and the positive electrode/aluminum layer. This intermediary provides electrical insulation, preventing direct contact and short circuits while allowing the conductive layer to perform its function of suppressing lithium abnormal precipitation.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Area of stationary object

If a long continuous separator is used to accommodate the electrode laminate, then the separator can cover the entire electrode structure, but the likelihood of contact between the conductive layer and positive electrode or aluminum layer increases due to displacement

Engineering Contradiction:
Improveseparator coverage areaVSAvoidshort circuit prevention
Core Design Contradiction:
Area of stationary objectVSReliability

Solution Approach 1:

The separator is segmented into multiple insulating layers, allowing the long continuous separator to provide comprehensive coverage while maintaining electrical insulation throughout its length, preventing short circuits even when displaced.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The separator uses composite material structure with insulating layers that provide both mechanical coverage and electrical insulation properties, enabling the separator to maintain reliability across large areas while preventing contact between conductive and positive electrode components.

Inventive Principle:
Principle #40Composite materials

Data Source

PatentUS20250309358A1Lithium metal secondary battery
Publication Date: 2025.10.02 HONDA MOTOR CO LTD
  • US20250309358A1 patent drawing
  • US20250309358A1 patent drawing
  • US20250309358A1 patent drawing

AI summary

Provided is a lithium metal secondary battery that is able to suppress short circuit in a lithium metal secondary battery using a separator having electrical conductivity. A lithium metal secondary battery includes an electrode laminate in which positive electrodes and negative electrode containing lithium metal are laminated with a separator interposed therebetween, and an electrolytic solution. The separator provided between the positive electrodes and the negative electrodes is folded in zigzag manner and is continuous. The lithium metal secondary battery further includes a fixing portion that fixes the separator on an outer peripheral side of the electrode laminate. The separator includes an electrically conductive layer having electric conductivity and an insulating layer having an electrical insulation property. Each of the negative electrodes is in contact with the electrically conductive layer. Each of the positive electrodes are opposed to the insulating layer.