Quasi-Solid Electrolyte Processing for Non-Flammable Lithium Cells

The patent changes the concentration parameter of lithium salt in the electrolyte from conventional low concentrations (0.5-2.0 M) to high concentrations (2.0-5.0 M). This parameter change transforms the electrolyte from a flammable liquid state to a non-flammable quasi-solid state, eliminating thermal runaway risks while maintaining ionic conductivity for lithium ion transport.

The patent creates a composite electrolyte system by combining lithium salt (LiPF6, LiBF4, or LiTFSI) with organic solvents (carbonate or ether families) in high concentrations. This composite formulation produces a quasi-solid electrolyte that integrates the ionic conductivity of liquid electrolytes with the safety of solid electrolytes, achieving both performance and safety.

The patent changes the electrolyte concentration parameter to high levels (2.0-5.0 M), which fundamentally alters the electrolyte's physical state and ion transport characteristics. This parameter change suppresses dendrite formation by creating a more uniform ion distribution and reducing local current density variations at the lithium metal anode surface.

The high concentration electrolyte acts as an intermediary medium between the lithium metal anode and cathode. It mediates the ion transport process by providing a stable, non-flammable environment that prevents direct harmful interactions while facilitating smooth lithium ion movement, thereby preventing dendrite growth and internal shorting.

The patent optimizes the lithium salt concentration parameter within a specific range (2.0-5.0 M) and selects appropriate solvent types (carbonate or ether families) to achieve the desired balance. This parameter optimization ensures that while flammability is eliminated through high concentration, the viscosity increase is controlled and ionic conductivity remains sufficient for practical battery operation.

The patent formulates a composite electrolyte using lithium salts combined with organic solvents in high concentrations. This composite approach creates a quasi-solid electrolyte that maintains adequate ionic conductivity by leveraging the synergistic effects of the salt-solvent interactions, achieving both safety and performance requirements simultaneously.

The patent changes the fundamental parameter of lithium salt concentration from conventional low levels to high levels (2.0-5.0 M). This parameter change transforms the electrolyte's physical properties, eliminating flammability while maintaining manageable viscosity through proper solvent selection and concentration control, making the safe electrolyte equally manufacturable.

The patent uses conventional, readily available organic solvents (carbonate or ether families) and lithium salts that are already widely used in the battery industry. By formulating these common materials at high concentrations, the patent achieves safe non-flammable electrolytes without requiring exotic or expensive materials, maintaining ease of manufacture and scalability.