Structural Battery Composite with Low Elastomer Binder
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Solution Overview
Problem
Conventional rechargeable batteries face challenges in achieving high energy density and long lifecycles due to structural limitations and the need for additional support structures, which reduce volumetric and gravimetric efficiency, and can lead to cracking and debonding during charging and discharging cycles.
Innovation Solution
A rechargeable battery with an anode and cathode structure formed from composite materials including electrically conductive fibers and electrochemically active materials in a binder matrix with less than 50% elastomer binder, providing structural rigidity and enhanced ion transport through the use of fluorinated elastomers, which also functions as a structural component, eliminating the need for separate support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional batteries use separate support structures, then structural stability is improved, but volumetric efficiency and gravimetric efficiency deteriorate
Solution Approach 1:
The patent merges the structural support function with the battery active materials by forming a composite structure where electrochemically active materials are embedded within a binder matrix that also provides mechanical support. This eliminates separate support structures and increases volumetric efficiency by integrating multiple functions into a single component.
Solution Approach 2:
The binder matrix serves multiple functions simultaneously: it provides structural support, binds electrochemically active materials, facilitates ion transport, and maintains electrode integrity during cycling. This multi-functionality eliminates the need for separate support structures and improves overall battery efficiency.
2Stability of the object's composition
If conventional batteries use separate support structures, then structural stability is improved, but device weight increases
Solution Approach 1:
The structural support function is merged with the battery active materials through a composite structure where the binder matrix provides both mechanical support and electrochemical functionality. This integration eliminates separate support structures and reduces overall device weight.
Solution Approach 2:
The patent extracts and eliminates separate support structures from the battery design, retaining only the essential binder matrix that provides both structural and electrochemical functions. This removal of redundant components directly reduces device weight.
3Quantity of substance
If porogens are used to increase energy density, then energy storage capacity is improved, but structural integrity deteriorates due to cracking and fatigue
Solution Approach 1:
The patent changes the binder matrix composition by incorporating elastomers and adjusting crosslinking density to achieve optimal balance between energy storage capacity and structural integrity. This parameter optimization prevents cracking and fatigue while maintaining high energy density.
Solution Approach 2:
The patent uses composite binder matrices combining elastomers, crosslinking agents, and other functional materials to create a structure that simultaneously provides high energy storage capacity and resistance to cracking. The composite nature allows synergistic properties that neither component alone could provide.
4Shape
If binder matrix contains high elastomer content, then flexibility is improved, but structural rigidity deteriorates
Solution Approach 1:
The patent optimizes the elastomer content parameter within specific ranges (5-50 wt%) and adjusts crosslinking density to achieve the optimal balance between flexibility and structural rigidity. This parameter control ensures the binder matrix remains flexible enough for ion transport while maintaining sufficient rigidity for structural support.
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
The solution results in a rechargeable battery with significantly increased energy storage capacity and extended lifecycles, improved mechanical properties, and reduced weight, making it suitable for structural applications where high energy density and durability are required, such as in aerospace and automotive industries.
Implementation Method 1
The elastomer binder preferably has the ability to undergo hydrogen-bonding, so as to promote ion transport within the anode/cathode structures
Implementation Method 2
provides pathways in the anode/cathode structures to promote the flow of ions
Data Source
AI summary
According to the invention there is provided a component including a rechargeable battery and a method of producing same. The component uses one of an acid and an alkaline chemistry and the battery has an anode structure, a cathode structure, and a separator structure which separates the anode from the cathode and contains an electrolyte. The anode structure and the cathode structure are each formed from a composite material which includes electrically conductive fibres and electrochemically active material in a binder matrix including less than 50% w/w of an elastomer binder and the battery is formed to be structurally inseparable from the rest of the component.