Semi-Solid Electrode Wetting to Limit Salt-Induced Degradation
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Solution Overview
Problem
Existing battery manufacturing methods face issues such as electrode degradation, moisture capture, and corrosion due to prolonged exposure to electrolyte salts, leading to performance degradation and safety risks, particularly with LiPF6 as a salt.
Innovation Solution
The method involves mixing an active material and conductive material with an electrolyte solvent to form a semi-solid electrode, followed by wetting with a concentrated electrolyte solution, minimizing direct contact with electrolyte salts to reduce degradation and corrosion, and allowing for safer, thicker electrodes with higher active material loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional slurry coating method is used with electrolyte salt present during manufacturing, then electrode assembly can be completed, but electrode degradation and corrosion occur leading to performance degradation
Solution Approach 1:
The patent applies preliminary action by pre-mixing the active material, conductive material, and binder with electrolyte solvent to form a semi-solid slurry before coating. This preliminary preparation ensures that the electrode structure is established without electrolyte salt present, preventing degradation and corrosion before they can occur during manufacturing operations.
Solution Approach 2:
The patent extracts the electrolyte salt from the slurry mixture during the manufacturing process. By separating the salt addition step from the slurry preparation and coating steps, the electrode structure is formed without exposure to corrosive electrolyte salts, and the salt is only introduced later when the electrode is already assembled and protected.
2Ease of manufacture
If electrolyte salt is present during electrode manufacturing, then conventional slurry can be formed, but moisture capture occurs leading to safety risks
Solution Approach 1:
The patent performs preliminary mixing of all slurry components except electrolyte salt before coating. This preliminary action allows the slurry to be properly formed and coated onto the current collector while avoiding moisture capture issues that would occur if electrolyte salt were present during these manufacturing steps.
Solution Approach 2:
The patent uses electrolyte solvent as an intermediary medium during slurry preparation and coating. The solvent allows proper slurry formation and coating without the harmful effects of electrolyte salt, and the actual electrolyte salt is introduced later through a separate wetting step after the electrode structure is already in place.
3Ease of manufacture
If conventional slurry with electrolyte salt is used, then electrode can be manufactured, but binding agent is required to ensure conductive networks, increasing complexity
Solution Approach 1:
The patent applies preliminary action by pre-mixing the active material, conductive material, and binder with electrolyte solvent to form a semi-solid slurry before coating. This preliminary preparation ensures proper mixing and distribution of all components including the binding agent, allowing the electrode structure to self-organize without requiring additional compression steps or complex assembly operations.
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 results in semi-solid electrodes with improved performance, reduced tortuosity, and increased energy density, along with enhanced safety and recyclability, while minimizing equipment usage and costs.
Implementation Method 1
wetting the semi-solid material with an electrolyte solution to form the semi-solid electrode
Implementation Method 2
The electrolyte salt can have a concentration in the electrolyte solution of at least about 1 M, at least about 2 M, or at least about 3 M
Data Source
AI summary
Embodiments described herein relate generally to semi-solid electrodes, and methods of producing the same. In some embodiments, a method of forming a semi-solid electrode can include mixing an active material, a conductive material, and an electrolyte solvent to produce a semi-solid material. The electrolyte solvent is free of electrolyte salt. The method further includes dispensing the semi-solid material onto a current collector and wetting the semi-solid material with an electrolyte solution to form the semi-solid electrode. In some embodiments, the wetting can be via spraying. In some embodiments, the electrolyte salt can have a concentration in the electrolyte solution of at least about 1 M, at least about 2 M, or at least about 3 M. In some embodiments, the solvent can include ethyl methyl carbonate (EMC), ethylene carbonate (EC), propylene carbonate (PC), dimethyl carbonate (DMC), gamma-Butyrolactone (GBL), or any combination thereof.