Gas-Phase Coated Lithium Metal Separator for Dendrite Control
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Solution Overview
Problem
Conventional lithium metal secondary batteries face challenges in maintaining energy density and stability due to the growth of lithium dendrite, which is exacerbated by the limitations of existing separator technologies that require extreme environmental conditions for manufacturing and result in reduced energy density and increased weight/volume.
Innovation Solution
A method involving the application of an oxidizing agent to a porous substrate followed by gas phase polymerization of a mixture containing a conductive monomer and an inorganic precursor to form a coating layer, enhancing the separator's heat resistance and electrical conductivity while preventing dendrite growth, all performed under mild conditions like room temperature and atmospheric pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sputtering is used to apply gold or copper to the separator, then electrical conductivity is improved and dendrite growth is suppressed, but manufacturing complexity increases due to vacuum atmosphere requirements
Solution Approach 1:
The patent replaces the mechanical vacuum sputtering process with a chemical vapor deposition approach using oxidizing agent solution and gas-phase polymerization. This substitution eliminates the need for vacuum equipment while achieving similar coating functions, thereby reducing manufacturing complexity while maintaining dendrite suppression capability
Solution Approach 2:
The patent changes the manufacturing parameters from vacuum conditions to atmospheric pressure conditions. By using gas-phase polymerization at atmospheric pressure instead of vacuum sputtering, the process becomes simpler and more compatible with standard manufacturing environments while still forming conductive coatings that suppress dendrite growth
2Stability of the object's composition
If a sandwich-type separator with inorganic coating layer is used, then thermal stability and electrolyte wettability are improved, but energy density decreases due to increased weight and volume
Solution Approach 1:
The patent employs a thin film coating layer formed through gas-phase polymerization that provides thermal stability and electrolyte wettability enhancement without the substantial thickness of sandwich-type separators. This thin film approach minimizes additional weight and volume, thereby preserving energy density while achieving the desired stability improvements
Solution Approach 2:
The patent creates a composite coating layer containing both organic polymer components (from conductive monomer polymerization) and inorganic materials (from inorganic precursor). This composite structure provides the thermal stability and chemical properties of inorganic materials while maintaining the flexibility and thin-film characteristics needed to minimize weight and volume impact on energy density
3Ease of manufacture
If conventional carbon-based active material is used, then manufacturing ease is maintained, but capacity is limited to 372 mAh/g
Solution Approach 1:
The patent changes the negative electrode material from conventional carbon-based materials to lithium metal, fundamentally altering the capacity parameter from 372 mAh/g to 3760 mAh/g. The separator modification enables this transition by providing the necessary dendrite suppression and stability that lithium metal requires, thus maintaining manufacturing feasibility while dramatically increasing capacity
4Reliability
If separator thickness is increased to improve stability, then dendrite growth is suppressed, but energy density is reduced due to increased weight and volume
Solution Approach 1:
The patent uses a thin film coating layer applied to the separator surface that provides dendrite suppression functionality without increasing the bulk separator thickness. This thin film approach maintains compact battery volume while achieving the necessary dendrite growth suppression, thereby preserving energy density
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 method improves energy density, heat resistance, and electrical conductivity of lithium metal secondary batteries, effectively preventing dendrite growth and enhancing safety by forming a thin film coating layer using conductive polymer resin and inorganic materials.
Implementation Method 1
applying an oxidizing agent to a porous substrate having pores such that the pores are maintained; and performing gas phase polymerization of a mixture including a conductive monomer and an inorganic precursor on the porous substrate
Implementation Method 2
performing gas phase polymerization of a mixture including a conductive monomer and an inorganic precursor on the porous substrate, such that a coating layer including a conductive polymer resin and an inorganic material is formed
Data Source
AI summary
The present disclosure relates to a method for manufacturing a separator for a lithium metal secondary battery, and a lithium metal secondary battery manufactured using the same, and specifically, to a method for manufacturing a separator for a lithium metal secondary battery, and a lithium metal secondary battery manufactured using the same, which suppress the growth of lithium dendrite and improve the stability, durability and electrical conductivity of a lithium metal secondary battery by coating a porous substrate with a thin film coating layer containing organic and inorganic materials.