Integrated Sintered Lithium Battery Separator for Electrode Alignment
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Solution Overview
Problem
Lithium secondary batteries with sintered plates face challenges in achieving high yield and excellent battery performance due to displacement issues between ceramic positive and negative electrodes, leading to reduced capacity and charge/discharge cycle performance.
Innovation Solution
A lithium secondary battery configuration where a positive electrode layer, ceramic separator, and negative electrode layer form an integrated sintered plate, with the ceramic separator composed of MgO and glass, having controlled grain sizes to ensure bonding and optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate ceramic positive electrode plate and negative electrode plate are used, then high capacity and good charge/discharge efficiency can be expected, but electrode displacement and waviness occur leading to reduced yield and performance
Solution Approach 1:
The patent combines the positive electrode layer, ceramic separator, and negative electrode layer into a single integrated sintered plate structure. This merging eliminates the displacement issues between separate ceramic electrodes while maintaining the high capacity and charge/discharge efficiency benefits of sintered plate electrodes.
Solution Approach 2:
The integrated sintered plate is segmented into distinct functional layers: positive electrode layer, ceramic separator, and negative electrode layer. Each layer maintains its specific properties while being bonded together as one integrated structure, allowing both high performance and high yield to be achieved.
2Productivity
If integrated sintered plate configuration is used, then production yield is improved, but electrode displacement and waviness reduce battery performance
Solution Approach 1:
By merging all electrode layers into one integrated sintered plate, the patent eliminates alignment and displacement issues that occur with separate electrodes. The entire structure is formed simultaneously through sintering, ensuring precise positioning of all layers.
Solution Approach 2:
The patent controls the grain size of glass (0.5 to 25 μm) and the ratio of glass grain size to MgO grain size (1.5 to 85) to optimize the bonding between layers. These parameter changes ensure proper adhesion and minimize waviness while maintaining high production yield.
3Ease of manufacture
If powder-dispersed positive electrode is used, then ease of manufacture is improved, but packing density of active material is low reducing capacity
Solution Approach 1:
The patent uses composite materials approach by combining sintered lithium complex oxide particles with controlled porosity (3 to 30%) and open pore rate (70% or more). This composite structure achieves high packing density of active material while maintaining manufacturability through the sintering process.
Solution Approach 2:
The patent changes the physical state of the positive electrode from powder-dispersed to sintered plate form. By controlling sintering parameters including grain size, porosity, and open pore rate, the patent achieves high active material packing density while keeping the manufacturing process feasible.
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 configuration enhances yield and battery performance by minimizing electrode displacement and waviness, achieving high discharge capacity and efficient charge/discharge cycles, suitable for IoT devices and other applications.
Implementation Method 1
a positive electrode layer, a ceramic separator, and a negative electrode layer form one integrated sintered plate as a whole
Data Source
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AI summary
Provided is a lithium secondary battery that is of the integrated sintered plate type in which a positive electrode layer, a ceramic separator, and a negative electrode layer are bonded together and that can achieve both high yield and excellent battery performance. The lithium secondary battery includes a positive electrode layer composed of a lithium complex oxide sintered body, a negative electrode layer composed of a titanium-containing sintered body, a ceramic separator, an electrolytic solution, and an exterior body including a closed space, the closed space accommodating the positive electrode layer, the negative electrode layer, the ceramic separator, and the electrolytic solution, wherein the positive electrode layer, the ceramic separator, and the negative electrode layer are bonded together, the ceramic separator is composed of MgO and glass, the glass has an average grain size of 0.5 to 25 µm, and a ratio of the average grain size of the glass to the average grain size of MgO is 1.5 to 85.