Semi-Solid Electrochemical Cells With Multiple Separators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrochemical cell production processes face significant costs due to electrolyte solvent evaporation, which can be costly to replace, and this evaporation hinders efficient production.
Innovation Solution
The use of multiple separators during the production process to minimize electrolyte solvent evaporation, combined with semi-solid electrodes that integrate liquid electrolyte throughout the manufacturing process, reducing evaporation and maintaining electrolyte volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional production processes are used with solid electrodes and electrolyte addition, then the manufacturing process is simple, but electrolyte solvent evaporates significantly during production
Solution Approach 1:
The patent applies preliminary action by incorporating the electrolyte into the electrode slurry before the electrodes are fully formed and before they undergo drying or assembly processes. This pre-incorporation ensures the electrolyte is already in place within the electrode structure, preventing evaporation losses that would occur if electrolyte were added later in the process.
Solution Approach 2:
The patent merges the electrolyte with the electrode materials (active material and conductive material) to form a unified semi-solid electrode structure. This combination creates an integrated system where the electrolyte is embedded within the electrode matrix, eliminating the need for separate electrolyte addition steps and preventing evaporation during subsequent manufacturing operations.
2Loss of substance
If semi-solid electrodes with integrated liquid electrolyte are used, then electrolyte evaporation is minimized, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by modifying the physical state of the electrode from conventional solid to semi-solid, and by changing the electrolyte concentration and viscosity parameters to enable the slurry formulation. These parameter adjustments allow the electrolyte to be integrated into the electrode matrix while maintaining manufacturability through controlled rheology and processing conditions.
3Quantity of substance
If multiple separators are used to prevent evaporation, then electrolyte volume is maintained, but the cell structure becomes more complex
Solution Approach 1:
The patent extracts the evaporation prevention function from the traditional separator component and transfers it to the electrode structure itself. By incorporating the electrolyte directly into the semi-solid electrode, the electrode assumes the role of retaining electrolyte volume, eliminating the need for additional separators dedicated to evaporation prevention and simplifying the overall cell structure.
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 significantly reduces electrolyte evaporation, maintaining electrolyte volume and enhancing the charge capacity and energy density of the electrochemical cells while simplifying the manufacturing process and reducing costs.
Implementation Method 1
Preventing solvent evaporation rather than replacing evaporated solvent can significantly reduce costs associated with production of electrochemical cells
Implementation Method 2
The anode material and/or the cathode material can be a semi-solid electrode material including an active material, a conductive material, and a volume of liquid electrolyte
Implementation Method 3
the method can further include wetting the first separator and/or the second separator with an electrolyte solution prior to coupling the first separator to the second separator
Data Source
AI summary
Embodiments described herein relate to electrochemical cells with multiple separators, and methods of producing the same. A method of producing an electrochemical cell can include disposing an anode material onto an anode current collector, disposing a first separator on the anode material, disposing a cathode material onto a cathode current collector, disposing a second separator onto the cathode material, and disposing the first separator on the second separator to form the electrochemical cell. The anode material and/or the cathode material can be a semi-solid electrode material including an active material, a conductive material, and a volume of liquid electrolyte. In some embodiments, less than about 10% by volume of the liquid electrolyte evaporates during the forming of the electrochemical cell. In some embodiments, the method can further include wetting the first separator and/or the second separator with an electrolyte solution prior to coupling the first separator to the second separator.