Multi-Separator Electrochemical Cells for Electrolyte Retention
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Solution Overview
Problem
Conventional electrochemical cell production processes face significant costs due to electrolyte solvent evaporation during the formation of semi-solid electrodes, leading to salt buildup and reduced efficiency in electroactive species transport.
Innovation Solution
The use of multiple separators during electrochemical cell production, coupled with semi-solid electrodes, minimizes electrolyte solvent evaporation by integrating liquid electrolyte throughout the manufacturing process, enhancing electrolyte retention and reducing tortuosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If semi-solid electrodes are formed by adding electrolyte solution to active material and conductive material, then electrode formation is achieved, but electrolyte solvent evaporates during production
Solution Approach 1:
The patent applies thin film separators that are disposed between electrode layers to create a closed structure that prevents electrolyte solvent evaporation. The separators act as barriers that retain the liquid electrolyte within the electrode assembly during production and operation, eliminating the harmful evaporation effect while maintaining ease of manufacture.
Solution Approach 2:
The patent converts the potential harm of electrolyte evaporation into a benefit by using the evaporation process to concentrate and saturate the electrolyte solution within the sealed electrode structure. This ensures complete wetting of separators and optimal electrolyte distribution without loss of solvent to the environment.
2Reliability
If multiple separators are used to prevent solvent evaporation, then electrolyte retention is improved, but device complexity increases
Solution Approach 1:
The patent designs separators that perform multiple functions simultaneously: they separate electrodes to prevent short circuits, provide pathways for ion transport through their porous structure, and act as barriers to prevent electrolyte evaporation. This multi-functionality reduces the need for additional components while maintaining high electrolyte retention.
Solution Approach 2:
The patent employs porous separator materials that allow efficient ion transport while maintaining structural integrity and preventing electrolyte leakage or evaporation. The porous structure provides adequate ion pathways without requiring multiple dense layers, thus reducing complexity while ensuring reliability.
3Productivity
If electrolyte solvent evaporates during production, then salt buildup occurs, but production costs increase due to need to replace solvent
Solution Approach 1:
The patent uses thin film separators to create a sealed environment that prevents electrolyte solvent evaporation during production. This eliminates the need to replace evaporated solvent, reducing production costs and maintaining productivity without material loss.
Solution Approach 2:
The patent converts the potential harmful effect of evaporation into a beneficial concentration process, where controlled evaporation or minimal loss leads to saturated electrolyte solution formation, ensuring optimal performance without requiring solvent replacement.
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
This approach reduces electrolyte evaporation to less than 10% by volume, maintaining high charge capacity and energy density while improving rate capability and reducing production costs.
Implementation Method 1
Preventing solvent evaporation rather than replacing evaporated solvent can significantly reduce costs associated with production of electrochemical cells
Implementation Method 2
the slurry can be moved from one location to another, and electrolyte solvent can evaporate from the slurry
Implementation Method 3
the first separator and/or the second separator can be composed of a material with a porosity of less than about 1%
Data Source
AI summary
Embodiments described herein relate to electrochemical cells with multiple separators, and methods of producing the same. A method of producing an electrochemical cell can include disposing an anode material onto an anode current collector, disposing a first separator on the anode material, disposing a cathode material onto a cathode current collector, disposing a second separator onto the cathode material, and disposing the first separator on the second separator to form the electrochemical cell. The anode material and/or the cathode material can be a semi-solid electrode material including an active material, a conductive material, and a volume of liquid electrolyte. In some embodiments, less than about 10% by volume of the liquid electrolyte evaporates during the forming of the electrochemical cell. In some embodiments, the method can further include wetting the first separator and/or the second separator with an electrolyte solution prior to coupling the first separator to the second separator.