Separator-Free Battery Laminate for Safer High-Density Cells
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Solution Overview
Problem
Existing battery technologies face challenges such as high production costs, complex manufacturing processes, stability and durability concerns, and toxicity issues, which hinder their widespread adoption and long-term sustainability.
Innovation Solution
A battery design that eliminates traditional separators by using a laminated structure comprising an ion transport layer and an electron insulation layer stacked together on the surfaces of electrode sheets, manufactured through evaporation deposition techniques to control layer thickness and optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separators are used in battery design, then ion transport and electrode separation are achieved, but production costs increase and manufacturing complexity increases
Solution Approach 1:
The patent combines the separator and protective coating functions into a single integrated laminated structure. This structure includes an ion transport layer (replacing traditional separators) and an electron insulation layer (providing protective coating), which are laminated together to form a unified component that performs multiple functions simultaneously, thereby reducing manufacturing complexity and production costs.
Solution Approach 2:
The patent employs composite materials in the form of a laminated structure consisting of different functional layers. The ion transport layer and electron insulation layer are made from different materials with specific properties, combined through lamination to create a composite structure that achieves both ion transport and protective functions, eliminating the need for separate components.
2Reliability
If nano-separators are used to achieve higher ionic conductivity and reduced thickness, then battery performance is improved, but production costs increase and susceptibility to damage occurs
Solution Approach 1:
The patent uses a composite laminated structure where the ion transport layer provides high ionic conductivity similar to nano-separators, but is combined with an electron insulation layer to create a more robust and cost-effective solution. This composite approach achieves the desired performance without the high production costs and fragility associated with pure nano-separator technologies.
Solution Approach 2:
The electron insulation layer acts as a protective cushion for the ion transport layer, preventing damage that could occur during assembly and use. This protective layer is applied beforehand to ensure the ion transport layer maintains its integrity and performance, addressing the susceptibility to damage issue without requiring expensive nano-materials.
3Reliability
If solid-state battery design is implemented to eliminate separators, then performance and safety are improved, but manufacturing complexity increases and production cost increases
Solution Approach 1:
Instead of implementing a complete solid-state battery design which requires complex manufacturing changes throughout the entire system, the patent applies local quality improvement by using a laminated structure with specific functional layers at critical locations. The ion transport layer provides separator-like functionality while the electron insulation layer enhances safety, achieving solid-state benefits in specific areas without requiring complete solid-state transformation.
Solution Approach 2:
The patent merges the separator elimination concept with traditional liquid electrolyte batteries by integrating ion transport and protection functions into laminated structures on existing electrode sheets. This approach combines the safety benefits of solid-state design with the manufacturing simplicity of conventional batteries, avoiding the need for completely new manufacturing processes.
4Reliability
If multi-layer separator design is used to enhance safety, then electron conduction blocking is improved, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple separator functions into a single laminated structure that includes an ion transport layer and an electron insulation layer. This integrated design blocks electron conduction and enhances safety without requiring multiple separate separator layers, heat welding, or adhesive bonding processes, thereby reducing manufacturing complexity and production costs.
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 design reduces material and labor costs, simplifies assembly, enhances stability by avoiding separator damage, and improves safety, resulting in a thinner battery with higher energy density and expanded applications.
Implementation Method 1
manufactured through evaporation deposition techniques to control layer thickness and optimize performance
Data Source
AI summary
The present application provides a battery, a method for manufacturing the battery, and an electric device. The battery includes a positive electrode sheet, a negative electrode sheet, and at least one laminated structure disposed on either the surface of the positive electrode sheet facing the negative electrode sheet or the surface of the negative electrode sheet facing the positive electrode sheet. The laminated structure includes an ion transport layer and an electron insulation layer stacked together. The battery does not include a separator.