Semi-Solid Electrochemical Cells With Selective Membrane Isolation
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Solution Overview
Problem
Conventional battery manufacturing methods result in batteries with lower capacity, lower energy density, and a high ratio of inactive components to active materials, due to complex and costly processes that include casting electrodes and using binders that increase tortuosity and decrease ionic conductivity.
Innovation Solution
The development of electrochemical cells with a selectively permeable membrane that chemically and/or fluidically isolates the anode from the cathode, allowing for the use of semi-solid electrodes with optimized catholyte and anolyte compositions, and eliminating the need for a conventional ion-permeable membrane separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional casting methods are used to manufacture electrodes, then the manufacturing process is complete and batteries can be produced, but the batteries have lower capacity and lower energy density
Solution Approach 1:
The patent extracts and removes the binder component from the electrode formulation, using only active material and conductive additive. This elimination of unnecessary components increases the ratio of active materials to inactive materials, thereby improving battery capacity and energy density while maintaining manufacturability through the slurry coating process
Solution Approach 2:
The patent uses a composite electrode structure consisting of active material particles and conductive additive particles distributed throughout a porous matrix. This composite approach optimizes both electrical conductivity and active material content, enabling higher capacity and energy density compared to conventional homogeneous electrode formulations
2Stability of the object's composition
If binders are used in electrode formulations, then the electrode structure is maintained, but tortuosity increases and ionic conductivity decreases
Solution Approach 1:
The patent removes binders from the electrode formulation entirely, relying on the porous network of active material and conductive additive particles to maintain structural integrity. This elimination eliminates the tortuosity and ionic resistance introduced by binder layers, significantly improving ionic conductivity while preserving electrode stability
Solution Approach 2:
The patent employs a porous electrode structure where the void spaces between particles serve dual functions: maintaining mechanical integrity without binders and providing low-resistance pathways for ion transport. The porous architecture reduces tortuosity and enhances ionic conductivity compared to dense binder-based structures
3Ease of manufacture
If conventional manufacturing processes are used, then batteries can be produced, but the ratio of inactive components to active materials is high
Solution Approach 1:
The patent extracts and eliminates binders from the electrode formulation, reducing the inactive component content. The slurry coating process maintains ease of manufacture by providing a simple, scalable method to apply the binderless electrode material onto current collectors, achieving high active material ratios without compromising production feasibility
Solution Approach 2:
The patent changes the formulation parameters by eliminating the binder component and adjusting the ratio of active material to conductive additive. This parameter change increases the active material content ratio while the slurry processing parameters (viscosity, coating thickness, drying conditions) are optimized to maintain ease of manufacture and production scalability
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 enhances the charge capacity and energy density of batteries by increasing the ratio of active materials to inactive materials, improving ionic conductivity, and reducing manufacturing complexity and costs, while also enhancing safety by reducing gas production and solvent leakage.
Implementation Method 1
a selectively permeable membrane disposed between the anode and the cathode, the selectively permeable membrane configured to chemically and/or fluidically isolate the anode from the cathode
Implementation Method 2
the selectively permeable membrane can include a solid-state electrolyte material
Implementation Method 3
the catholyte can be optimized to improve the redox electrochemistry of the cathode and the anolyte can be optimized to improve the redox electrochemistry of the anode
Data Source
AI summary
Embodiments described herein relate generally to electrochemical cells including a selectively permeable membrane and systems and methods for manufacturing the same. In some embodiments, the selectively permeable membrane can include a solid-state electrolyte material. In some embodiments, electrochemical cells can include a cathode disposed on a cathode current collector, an anode disposed on an anode current collector, and the selectively permeable membrane disposed therebetween. In some embodiments, the cathode and/or anode can include a slurry of an active material and a conductive material in a liquid electrolyte. In some embodiments, a catholyte can be different from an anolyte. In some embodiments, the catholyte can be optimized to improve the redox electrochemistry of the cathode and the anolyte can be optimized to improve the redox electrochemistry of the anode. In some embodiments, the selectively permeable membrane can be configured to isolate the catholyte from the anolyte.