Porous Solid-State Electrolyte Foam Battery Cell Design
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Solution Overview
Problem
All-solid-state batteries face challenges in achieving good electrolyte distribution within thicker electrodes and at interfaces with separators, leading to reduced energy and power performance due to resistance and mechanical weaknesses, with existing methods focusing primarily on electrode-scale ion transport and not addressing the complete battery cell environment.
Innovation Solution
A battery cell design featuring positive and negative electrodes composed of porous solid-state electrolyte polymer foams, where lithium salts and active materials are incorporated within the foams, and a polymer film separator, forming a one-piece structure without physical interfaces to enhance ion transport and reduce resistance across the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thicker electrodes are used to increase energy density, then the amount of active material increases, but the distribution of solid-state electrolyte becomes poor and ion transport is hindered
Solution Approach 1:
The patent employs porous solid-state electrolyte materials with controlled pore structures that enable uniform electrolyte distribution throughout thick electrodes. The porous architecture allows ion transport pathways to extend deep into the electrode bulk, maintaining electrolyte presence and ion conductivity even at large thicknesses where conventional dense electrolytes would fail to distribute properly.
2Ease of manufacture
If solid-state electrolyte is added directly during electrode shaping, then the process is simplified, but the dispersion of constituents becomes difficult and electrolyte distribution deteriorates
Solution Approach 1:
The patent modifies the physical and chemical parameters of the solid-state electrolyte material, specifically controlling pore size distribution, porosity levels, and surface area characteristics. These parameter changes enable the electrolyte to disperse uniformly during the electrode shaping process while maintaining structural integrity and ion transport capabilities, resolving the conflict between process simplicity and dispersion quality.
3Reliability
If nonporous separator film is used for electrical insulation, then separator function is achieved, but interface resistance increases and ion transport is limited
Solution Approach 1:
The patent applies local quality modification by creating porous regions in the separator film at the interfaces with electrodes, while maintaining nonporous structure in the bulk for electrical insulation. This localized porosity reduction enables better electrolyte penetration and reduced interface resistance at critical electrode-separator boundaries, while the overall separator maintains its insulating function.
4Reliability
If interface between electrode and separator is created, then electrical insulation is provided, but mechanical weakness and resistance zones are introduced
Solution Approach 1:
The patent merges the electrode and separator into a single integrated structure where the porous solid-state electrolyte extends continuously from the electrode bulk through the separator interface. This merging eliminates the discrete interface boundary, creating a continuous ion transport pathway that removes mechanical weakness zones and resistance barriers while maintaining electrical insulation through the inherent properties of the solid-state electrolyte material.
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 design ensures uniform ion transport throughout the battery, eliminating interface resistance and mechanical weaknesses, thereby improving energy and power performance while maintaining durability.
Implementation Method 1
ion transport at the electrode scale takes place through the network formed by the solid electrolyte... this network is percolated, forming ionic conduction paths through the entire volume of the electrode
Implementation Method 2
this network is percolated, forming ionic conduction paths through the entire volume of the electrode, to ensure the transport of the ions to or from the assembly of active material particles
Data Source
AI summary
A battery cell includes at least one positive electrode, at least one negative electrode, and at least one separator. The positive electrode includes a positive electrode porous solid-state electrolyte polymer foam that includes at least one lithium salt, and a positive electrode material located in the pores of the positive electrode foam. The negative electrode includes a negative electrode porous solid-state electrolyte polymer foam that includes at least one lithium salt, and a negative electrode material located in the pores of the negative electrode foam.