Nanoporous Separator-Electrode Assembly for Higher-Density Lithium Batteries
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Lithium batteries face limitations in energy and power density due to thick, non-electrochemically active separator and metal substrate layers, which also increase manufacturing complexity and cost, particularly in high-power applications like hybrid and electric vehicles.
Innovation Solution
The use of nanoporous separators with a thickness of less than 9 microns and current collector layers thinner than 3 microns, allowing for direct coating of electrode layers on the separator, and a method of laminating these layers to form a separator/electrode assembly with a current collector interposed between electrode layers of opposite polarity, reducing the complexity and cost of battery fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick separators and metal substrates are used to maintain mechanical strength and integrity, then structural reliability is improved, but the volume proportion of electroactive material decreases, reducing energy density
Solution Approach 1:
The patent employs nanoporous separators with controlled pore structures that provide mechanical integrity while maintaining thin profiles. The porous architecture allows the separator to achieve sufficient strength at reduced thickness compared to solid non-porous separators, thereby increasing the volume available for electroactive materials without compromising structural reliability.
Solution Approach 2:
The invention changes the physical parameters of the separator and current collector layers by reducing their thickness to nanoscale dimensions (separator < 9 microns, current collector < 3 microns). This parameter change enables the thin layers to maintain adequate mechanical properties while significantly increasing the proportion of electroactive material in the battery structure.
2Manufacturing precision
If automated interleaving equipment is used to maintain alignment and quality, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the separator and current collector layers into a single integrated assembly structure, where the thin separator is positioned between electroactive material layers and current collectors during the coating process. This integration eliminates the need for separate automated interleaving equipment to align multiple independent components, thereby reducing manufacturing complexity while maintaining alignment precision.
Solution Approach 2:
The invention performs preliminary positioning of the separator and current collector layers during the coating process itself, rather than requiring subsequent alignment steps. By establishing the correct layer configuration early in manufacturing, the need for complex automated interleaving equipment is eliminated, simplifying the overall manufacturing system.
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 enhances energy and power densities while simplifying and cost-reducing the manufacturing process, making lithium batteries more suitable for high-power applications like electric vehicles.
Implementation Method 1
nanoporous separators with a thickness of less than 9 microns
Data Source
AI summary
Provided are methods of preparing lithium batteries comprising a separator/electrode assembly having one or more current collector layers interposed between first and second electrode layers of the same polarity, wherein the first electrode layer is coated or laminated overlying a separator layer and the separator/electrode assembly is interleaved with an electrode comprising a current collector layer interposed between two electrode layers of opposite polarity to said first and second electrodes.