Multiple-Separator Electrochemical Cells for Low Electrolyte Evaporation
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Solution Overview
Problem
Conventional electrochemical cell production processes face significant costs due to electrolyte solvent evaporation, which can be costly to replace, and this evaporation hinders the efficient production of semi-solid electrodes.
Innovation Solution
The use of multiple separators during the production process to minimize electrolyte solvent evaporation, combined with semi-solid electrodes that integrate liquid electrolyte throughout the manufacturing process, reducing evaporation and maintaining electrolyte volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional production processes are used with solid electrodes and electrolyte addition, then the production process is simple, but electrolyte solvent evaporates significantly during production
Solution Approach 1:
The patent applies preliminary action by incorporating the electrolyte into the electrode slurry before the evaporation problem occurs during production. The electrolyte is mixed with the active material and conductive material in the slurry formulation, creating a self-contained electrode structure that prevents subsequent solvent loss during manufacturing processes.
Solution Approach 2:
The patent uses composite materials by creating a semi-solid electrode that integrates multiple components (active material, conductive material, and liquid electrolyte) into a unified slurry structure. This composite approach allows the electrolyte to be bound within the electrode matrix, preventing evaporation while maintaining electrochemical functionality.
2Ease of manufacture
If electrolyte is added after electrode formation, then the production process is straightforward, but replacing evaporated solvent increases production costs
Solution Approach 1:
The electrolyte is incorporated into the electrode slurry before production, performing the electrolyte addition action in advance. This eliminates the need for post-formation electrolyte replenishment and prevents the quantity loss that would require costly replacement during manufacturing.
Solution Approach 2:
The electrode slurry is formulated to be self-sufficient with integrated electrolyte, allowing the electrode to maintain its own electrolyte volume without external replenishment. The semi-solid structure inherently preserves the electrolyte, making the system self-maintaining during production and operation.
3Loss of substance
If semi-solid electrodes with integrated electrolyte are used, then electrolyte evaporation is minimized, but the production process complexity increases
Solution Approach 1:
The patent changes the physical state parameter of the electrode from conventional solid to semi-solid slurry form. This parameter change enables the electrolyte to be integrated within the electrode matrix, preventing evaporation through the slurry's inherent structure rather than requiring complex containment systems.
Solution Approach 2:
By creating a composite slurry material combining active material, conductive material, and liquid electrolyte, the patent achieves evaporation prevention through material composition rather than process complexity. The composite structure naturally retains the electrolyte while allowing relatively simple production handling.
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 significantly reduces electrolyte solvent evaporation, maintaining electrolyte volume and enhancing the charge capacity, energy density, and operational efficiency of electrochemical cells, while also providing overcharge protection and improved diagnostics for cell health monitoring.
Implementation Method 1
The use of multiple separators during the production process to minimize electrolyte solvent evaporation
Implementation Method 2
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
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.