Pulse-Charge Battery Formation for Uniform SEI Layers
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Solution Overview
Problem
Current battery formation processes are lengthy, expensive, and result in non-uniform SEI layers, leading to degraded battery performance and significant energy losses.
Innovation Solution
A method involving a sequence of pulse charging cycles with alternating positive and negative pulses, including a net zero charge phase, a net positive charge phase, and a final net zero charge phase, to control the formation of a uniform SEI layer, using a controller to monitor and adjust parameters like SEI thickness and state of charge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional continuous charging methods are used for battery formation, then the battery can be charged, but the formation time is lengthy and energy losses are significant
Solution Approach 1:
The patent applies periodic pulsed charging instead of continuous charging. The controller delivers charging current in discrete pulses with specific duty cycles (e.g., 50% duty cycle where charge and discharge phases are equal in duration), allowing the battery to rest between pulses. This periodic action accelerates SEI layer formation while reducing overall formation time and energy consumption compared to conventional continuous charging methods.
2Manufacturing precision
If conventional charging methods are used, then charging can proceed continuously, but the SEI layer formed is non-uniform leading to degraded battery performance
Solution Approach 1:
The pulsed charging method creates periodic formation conditions that promote uniform SEI layer growth. By alternating between charge and discharge phases within each pulse cycle, the method ensures even distribution of lithium ions across the electrode surface, preventing localized thick or thin SEI regions. This results in uniform SEI layers that improve battery reliability and performance consistency.
Solution Approach 2:
The patent dynamically adjusts pulse parameters (duty cycle, frequency, amplitude) based on battery state and formation progress. The controller modifies pulse characteristics in real-time to optimize SEI layer formation uniformity at different stages of the process, adapting to changing battery conditions to maintain consistent quality throughout formation.
3Device complexity
If conventional formation processes are used, then the process is simple, but energy losses are significant
Solution Approach 1:
The periodic pulsed charging method reduces energy losses by allowing the battery to rest between pulses. During the discharge phase of each pulse cycle, excess energy is dissipated safely, and during rest periods, the battery stabilizes, reducing heat generation and energy waste. This approach cuts formation time by up to 50% compared to continuous charging, directly reducing total energy consumption despite adding pulse control 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
This approach reduces formation time, enhances SEI layer uniformity, and improves battery performance by enabling faster charging and capacity retention.
Implementation Method 1
measuring a first battery parameter... determining a thickness of solid electrolyte interphase (SEI) layer of the battery
Data Source
AI summary
Disclosed are methods, systems, and devices for battery formation. A first set of pulses, having a first frequency, and that carry a net zero charge, are applied to a battery. After the first set of pulses are applied to the battery, a second set of pulses that carry a net positive charge are applied to the battery. The second set of pulses are either applied after expiry of a particular time period following the application of the first set of pulses, or based on some battery measurements. After the second set of pulses are applied to the battery, a battery parameter is measured, and based on the measured battery parameter, a third set of pulses, having a second frequency, and that also carry a net zero charge, are applied to the battery.