Printed Electrochemical Cell Separators That Resist Dendrite Puncture
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Solution Overview
Problem
The manufacturing of thin film electrochemical cells is hindered by the difficulty in producing cost-effective and time-efficient separators that are robust enough to prevent internal short circuits caused by dendritic growth on electrodes.
Innovation Solution
A method of printing separators using an ink comprising particles of a separator-forming substance suspended in a solvent, which can be dried or cured to form a robust, ion-conducting layer that resists puncture and allows ion passage, suitable for thin and flexible electrochemical cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer gel inks are used to print separators, then the manufacturing process becomes simpler and more cost-effective, but the separator structure becomes too weak to resist dendritic growth causing short circuits
Solution Approach 1:
The patent changes the material composition parameters by using inorganic particles (such as metal oxides, metal nitrides, or metal carbides) instead of organic polymer gel. This fundamental material parameter change provides both the desired mechanical strength to resist dendrites and the ionic conductivity needed for separator function, while maintaining ease of manufacture through printing processes.
Solution Approach 2:
The patent creates a composite separator structure by suspending inorganic particles in a binder matrix. This composite approach combines the mechanical strength and thermal stability of inorganic materials with the processability of printed materials, achieving both strength and manufacturability simultaneously.
2Length of moving object
If separator thickness is reduced to enable thin film electrochemical cells, then device compactness improves, but the separator becomes more susceptible to puncture by dendrites
Solution Approach 1:
The patent changes the material density and mechanical properties by using inorganic particles with high compressive strength. This allows the separator to maintain adequate puncture resistance even at reduced thicknesses, enabling thin film electrochemical cells while preventing dendrite penetration.
Solution Approach 2:
The patent develops a thin film separator structure that is both mechanically robust and ionically conductive. The inorganic particle-based composition enables the creation of thin films that maintain structural integrity and dendrite resistance despite the reduced thickness, facilitating compact electrochemical cell designs.
3Strength
If traditional separator manufacturing methods are used, then separator robustness is achieved, but production time increases and cost efficiency decreases
Solution Approach 1:
The patent replaces traditional mechanical separator manufacturing processes (such as extrusion or compression molding) with a printing process. This substitution enables direct deposition of the separator material in the desired shape and location, significantly reducing production time and increasing efficiency while maintaining robustness through the inorganic particle composition.
Solution Approach 2:
The patent changes the manufacturing approach by using a printable ink formulation containing inorganic particles suspended in a binder. This parameter change in material form (from bulk material requiring mechanical processing to printable suspension) enables rapid, cost-effective production while maintaining the robustness associated with inorganic separator materials.
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 method enables the rapid and efficient production of robust separators that prevent short circuits in thin film electrochemical cells, facilitating the mass production of flexible and portable energy storage devices.
Implementation Method 1
The step of forming the separator optionally comprises drying or curing the ink
Implementation Method 2
The step of forming the separator optionally comprises drying or curing the ink
Implementation Method 3
providing an ink comprising particles of a separator-forming substance suspended therein
Implementation Method 4
Drying or curing the ink may comprise applying a laser to the ink
Implementation Method 5
Drying or curing the ink may comprise applying heat to the ink
Data Source
AI summary
Method of printing and articles A method of printing a separator for an electrochemical cell and articles made therefrom. A method of printing a separator for an electrochemical cell and a method of printing an electrochemical cell comprises providing an ink having particles of a separator-forming substance suspended within it and printing a layer of the ink onto a surface. The separator is formed from the separator-forming substance in the layer of ink. This may be done by drying or curing the layer of ink. The separa-tor-forming particles may host an electrolyte before or after the separator is formed.