Polymeric Battery Support Structure for Delamination Resistance
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Solution Overview
Problem
Lithium-based batteries experience volumetric changes due to gas formation, leading to electrode separation and delamination, which degrades ion transfer paths and results in cell failure, with conventional metal-based compressive structures increasing weight and cost while limiting performance.
Innovation Solution
A polymeric support system is used as a compressive structure within the battery, comprising a continuous network of polymers that provides mechanical strength and anchors to the electrodes, reducing overall weight and volume, and can be cured using optical, chemical, or kinetically controlled methods to optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal-based compressive structures are used to prevent electrode separation, then mechanical strength is improved, but weight increases substantially
Solution Approach 1:
The patent changes the material parameter from metal to polymer, fundamentally altering the density and mechanical properties. The polymer support structures provide sufficient mechanical strength to resist electrode separation while weighing significantly less than metal alternatives, directly resolving the weight-strength contradiction.
Solution Approach 2:
The patent employs composite polymer structures that combine multiple polymer components or polymer-reinforcement combinations to achieve the necessary mechanical strength. These composite materials provide adequate structural support to prevent delamination without the excessive weight of metal compressive structures.
2Reliability
If metal-based compressive structures are used to maintain cell integrity, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from metal to polymer, which are inherently less expensive materials. This substitution reduces both material costs and manufacturing costs while maintaining the functional requirement of preventing electrode separation and maintaining cell integrity throughout battery operation.
Solution Approach 2:
The patent employs cost-effective polymer materials that, while potentially having different lifecycle characteristics than metal, provide sufficient durability for the battery's operational life at a fraction of the cost of metal compressive structures, reducing overall manufacturing expenses.
3Strength
If metal-based compressive structures are used to prevent delamination, then mechanical strength is improved, but battery performance is limited
Solution Approach 1:
The patent changes the material parameter from metal to polymer, reducing the mass of the support structures. This weight reduction improves the power-to-weight ratio and energy density of the battery, enhancing overall performance metrics such as range and efficiency while maintaining sufficient mechanical strength to prevent delamination.
4Weight of moving object
If polymer support system is used to reduce weight, then weight is reduced, but mechanical strength may be compromised
Solution Approach 1:
The patent employs composite polymer structures that combine multiple polymer components or polymer-reinforcement combinations to achieve the necessary mechanical strength. These composite materials provide adequate structural support to prevent delamination without the excessive weight of metal compressive structures.
Solution Approach 2:
The patent employs three-dimensional polymer support structures, such as lattice or foam architectures, that provide mechanical strength through geometric design rather than material density alone. This dimensional approach allows lightweight polymer materials to achieve the necessary structural integrity to resist electrode separation forces.
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 polymeric support system enhances mechanical strength, reduces weight and volume, and improves electrochemical conditions within the battery, enabling more efficient operation and extended lifespan while minimizing the need for metal-based structures.
Implementation Method 1
the polymeric support system may be cured using optical energy (e.g., gamma, X-ray, ultraviolet, etc.)
Data Source
AI summary
Electrochemical cells and batteries including a polymeric support system in lieu of a conventional, metal-based structures. The polymer support system provides mechanical strength and mechanical flexibility to the electrochemical cells in a manner that is advantageously greater than what is provided by conventional structures, in spite of the fact that the polymer support system contributes far less to the overall weight of the electrochemical cells. The polymer support system may be present in an interior volume of an electrochemical cell, e.g., in the form of a continuous polymeric network penetrating various components of the electrochemical cell. The penetrating structures may include the anode and cathode current collectors, and any/all components therebetween. Additionally or alternatively, the polymer support system may include various forms of external support structures, chemical anchors, coatings and/or casings of the electrochemical cell. Additional advantageous characteristics include improved recyclability and increased longevity of the electrochemical cells.