Monolithic Ceramic Cell with Sealed Anode for Dendrite Prevention
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Solution Overview
Problem
Current lithium ion batteries face challenges such as high manufacturing costs, low energy density, and limitations due to liquid electrolytes, which restrict the use of lithium metal anodes and result in dendrite formation, limited voltage, and poor sealing, leading to reduced capacity and safety issues.
Innovation Solution
A monolithic ceramic electrochemical cell housing with hermetically sealed anode receptive spaces filled with high-density ceramic electrolyte strands and integrated electron conductive circuits, along with a manufacturing method using multi-material additive processes to create a continuous ionic conductivity network and a hybrid cell design that incorporates a hermetically sealed anode and a cathode with similar composition to conventional lithium ion cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium metal anodes are used, then energy density is improved, but dendrite formation occurs causing safety issues
Solution Approach 1:
A solid electrolyte layer is introduced as an intermediary between the lithium metal anode and cathode. This solid electrolyte acts as a physical barrier that prevents direct contact and dendrite penetration while still allowing lithium ion transport, thus maintaining the high energy density benefits of lithium metal while eliminating the safety hazards of dendrite formation and liquid electrolyte combustion
Solution Approach 2:
The electrolyte phase is changed from liquid to solid state. This parameter change fundamentally alters the properties of the electrolyte: solid electrolytes have higher mechanical strength to resist dendrite penetration, higher thermal stability to prevent combustion, and can operate at higher voltages. This transformation enables the use of lithium metal anodes by providing a safe interface that maintains ionic conductivity while preventing harmful dendrite growth
2Reliability
If liquid electrolyte is used, then ionic conductivity is maintained, but maximum voltage is limited to about 3.8-volts
Solution Approach 1:
The electrolyte is transformed from liquid to solid state, which fundamentally changes its electrochemical stability window. Solid electrolytes can withstand potentials above 6 volts between anode and cathode without decomposition, compared to liquid electrolytes that decompose above 3.8 volts. This parameter change enables the use of high-voltage cathode materials that can produce 6 volts against a lithium anode, increasing energy density by 50% while the solid state maintains ionic conductivity through crystal lattice pathways
3Reliability
If liquid electrolyte is used, then dendrite growth is prevented, but the electrolyte is highly combustible causing safety hazards
Solution Approach 1:
The electrolyte phase is changed from liquid to solid, which fundamentally alters its safety properties. Solid electrolytes are non-flammable and thermally stable, eliminating the combustion hazard of liquid electrolytes. Simultaneously, the solid state provides mechanical strength to physically block dendrite penetration, combining both dendrite prevention and fire safety in a single material phase change
Solution Approach 2:
The rigidity and brittleness of ceramic materials, which were initially seen as drawbacks, are converted into benefits. The mechanical strength of solid electrolytes provides physical barrier properties that actively prevent dendrite penetration, transforming the previously harmful rigidity into a protective feature that enhances both safety and dendrite resistance simultaneously
4Power
If ceramic electrolyte is used, then high voltage stability is achieved, but manufacturing complexity increases due to rigid and brittle properties
Solution Approach 1:
The cell structure is segmented into discrete layers with the solid electrolyte forming distinct interfaces between anode and cathode compartments. This segmentation allows each layer to be optimized independently and facilitates assembly through layer-by-layer construction, reducing the overall manufacturing complexity despite the inherent challenges of working with ceramic materials
Solution Approach 2:
The solid electrolyte layer performs multiple functions simultaneously: it serves as the ionic conductor, the physical barrier against dendrites, the separator between electrodes, and the structural element defining cell compartments. This multi-functionality reduces the total number of components needed and simplifies the overall cell architecture, offsetting some of the manufacturing complexity introduced by using ceramic materials
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 achieves lower per watt costs, significantly higher volumetric energy densities, and a safer, more efficient energy storage capacity by eliminating the drawbacks of traditional lithium ion batteries, including dendrite formation and limited voltage, while maintaining ionic conductivity across the electrode space regardless of charge state.
Implementation Method 1
ceramics with high lithium ion conductivities meet those requirements
Implementation Method 2
Any oxygen or water ingress into the anode space will cause oxidation of the lithium
Data Source
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AI summary
A monolithic ceramic electrochemical cell housing is provided. The housing includes two or more electrochemical sub cell housings. Each of the electrochemical sub cell housing includes an anode receptive space, a cathode receptive space, a separator between the anode receptive space and the cathode receptive space, and integrated electron conductive circuits. A first integrated electron conductive circuit is configured as an anode current collector within the anode receptive space. A second integrated electron conductive circuit is disposed as a cathode current collector within the cathode receptive space.