Porous Electrode-Separator Assembly for Uniform Charge Distribution
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Solution Overview
Problem
Conventional lithium-ion batteries face challenges in achieving high energy and power densities while ensuring safety, stability, and long cycle life due to non-homogeneous particle sizes, organic binder issues, and the risk of dendrite formation, along with high manufacturing costs and complex ink formulations.
Innovation Solution
A porous electrode/separator assembly is developed using nanoparticles agglomerates with controlled porosity and homogenous pore sizes, devoid of organic binders, and impregnated with ionic liquids, combined with a ceramic separator, to enhance dynamic balancing and mechanical stability, and a conductive coating is applied to improve electronic conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional coating techniques with particles of 5-15 μm are used, then the manufacturing process is simple, but the energy and power density cannot be simultaneously optimized
Solution Approach 1:
The patent segments the particle size distribution into multiple ranges (0.5-5 μm, 5-15 μm, 15-30 μm) with different functional roles: fine particles fill voids to reduce porosity and increase energy density, while coarser particles maintain porosity for ion transport and power density. This segmentation allows simultaneous optimization of both energy and power density through a coordinated multi-size particle system.
2Quantity of substance
If the porosity of electrodes is reduced to increase active ingredient density, then the energy density increases, but the power density and ion transport capability decrease
Solution Approach 1:
The patent applies local quality by creating spatially differentiated porosity: regions with fine particles (0.5-5 μm) have reduced porosity (20-40%) to maximize active ingredient density and energy storage, while regions with coarser particles (15-30 μm) maintain higher porosity (40-60%) to ensure rapid ion transport and power delivery. This local differentiation resolves the contradiction between energy and power density.
3Reliability
If non-homogeneous particle sizes are used, then the manufacturing process is simpler, but uniform charge distribution cannot be achieved leading to hot spots
Solution Approach 1:
The patent changes the particle size parameter from a single broad distribution to a controlled multi-modal distribution with specific size ranges (0.5-5 μm, 5-15 μm, 15-30 μm) and controlled proportions (10-40%, 40-60%, 10-30%). This parameter control ensures uniform charge distribution across different particle sizes, preventing hot spots while maintaining manufacturing feasibility through established coating techniques.
4Strength
If organic binders are used in electrode manufacturing, then the structural integrity is maintained, but safety issues and manufacturing complexity increase
Solution Approach 1:
The patent extracts and eliminates organic binders from the electrode formulation, relying instead on the mechanical interlocking and contact between particles of different sizes to maintain structural integrity. The multi-size particle system (0.5-30 μm) creates a self-supporting structure where finer particles fill voids between coarser particles, providing structural stability without organic additives, thereby improving safety and reducing manufacturing complexity.
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 results in a battery with high energy and power densities, improved safety, and extended cycle life, along with reduced manufacturing complexity and cost, by ensuring uniform charge distribution and avoiding hot spots.
Implementation Method 1
provision is made of a substrate, a first colloidal suspension comprising aggregates or agglomerates of monodisperse primary nanoparticles
Implementation Method 2
said layer obtained in step (b) is dried, where appropriate before or after having separated said layer from its intermediate substrate
Data Source
AI summary
A method for manufacturing an electrochemical device that may be selected from the group consisting of: lithium ion batteries with a capacity greater than 1 mAh, capacitors, supercapacitors, resistors, inductors, transistors, photovoltaic cells, fuel cells, implementing a method for manufacturing an assembly comprising a porous electrode and a porous separator comprising a porous layer deposited on a substrate having a porosity comprised between 20% and 60% by volume, and pores with an average diameter of less than 50 nm.