TAB-Less Cylindrical Li-S Battery Winding Against Polysulfide Shuttle
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Solution Overview
Problem
Conventional lithium-sulfur batteries face issues with polysulfide shuttle effect, leading to loss of active material, reduced cycling stability, and potential cell failure due to lithium dendrite formation and corrosion, limiting their performance in applications requiring high energy density.
Innovation Solution
A method for manufacturing a lithium-sulfur battery in a cylindrical cell format using a protective layer of wrinkled graphene nanoplatelets with fluorinated poly(meth)acrylates, an adhesive carbon-containing layer, and a porous carbonaceous cathode structure to inhibit polysulfide migration and enhance electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lithium-sulfur batteries are manufactured without protective layers, then manufacturing process is simple, but polysulfide shuttle effect causes loss of active material and reduced cycling stability
Solution Approach 1:
A protective layer is deposited on the anode current collector before the anode is formed. This preliminary protective coating prevents polysulfide migration and lithium dendrite formation from the outset, addressing the reliability issue before the battery begins operation.
Solution Approach 2:
The protective layer acts as an intermediary between the anode current collector and the anode, mediating the interaction to prevent harmful polysulfide shuttle effect and lithium dendrite formation while maintaining electrical conductivity through carbonaceous materials.
2Quantity of substance
If tabs are used in conventional batteries, then electrical connection is established, but tab materials may cause corrosion and reduce energy density
Solution Approach 1:
The patent removes traditional metal tabs from the battery structure entirely. Instead, current collection is achieved through the anode current collector itself and conductive carbonaceous materials integrated into the anode structure, eliminating the corrosion issue associated with tab materials.
Solution Approach 2:
The anode current collector serves multiple functions: it provides mechanical support, enables current collection, and prevents polysulfide migration. The conductive carbonaceous materials in the anode structure also serve dual purposes of maintaining electrical conductivity and preventing corrosion, replacing the specialized function of tabs.
3Strength
If adhesive layers are added to prevent delamination, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The protective layer and adhesive function are merged into a single integrated layer. This multi-functional layer simultaneously provides protection against polysulfide migration, prevents delamination through adhesive properties, and maintains electrical conductivity, reducing the number of separate components needed.
Solution Approach 2:
The protective layer is formulated as a composite material containing carbonaceous materials for conductivity, adhesive components for bonding, and protective agents for preventing polysulfide migration. This composite approach consolidates multiple functions into one material system.
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 method improves electrical discharge performance, increases battery capacity retention, and maintains structural integrity by preventing delamination and lithium erosion, enabling higher energy density and stability in lithium-sulfur batteries.
Implementation Method 1
depositing a protective layer on and along the length of the anode. For example, the protective layer may include wrinkled graphene nanoplatelets adjoined to one another by flexure points
Implementation Method 2
fluorinated poly(meth)acrylates may be grafted onto some exposed carbon atoms
Implementation Method 3
disposing an adhesive carbon-containing layer along the bottom edge of the anode
Implementation Method 4
dispersing an electrolyte throughout the lithium-sulfur battery such that the electrolyte may be dispersed throughout the cathode and contact the anode
Implementation Method 5
carbonaceous materials replacing one or more anode tabs, thereby providing increased electrical conductivity relative to conventional jelly roll batteries
Data Source
AI summary
A method of manufacturing a lithium-sulfur battery in a cylindrical cell format is provided. In some aspects, the method includes providing an anode current collector and providing an anode on the anode current collector. The method may include depositing a protective layer on and along the length of the anode, providing a cathode current collector opposite to the anode, and providing a cathode on the cathode current collector. The method may include providing a separator between the anode and the cathode, disposing an adhesive carbon-containing layer along the bottom edge of the anode (e.g., to replace one or more conventional anode tabs), and dispersing an electrolyte throughout the lithium-sulfur battery. The method may include forming the lithium-sulfur battery in the cylindrical cell format by collectively winding into a jelly roll.