Continuous Thick-Electrode Cell Production With Quasi-Solid Electrolyte
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Solution Overview
Problem
Current lithium-ion batteries face limitations in gravimetric and volumetric energy densities, power densities, and safety due to low active material mass loadings, electrode thickness constraints, and inefficient manufacturing processes, which hinder their application in high-energy-demanding fields like electric vehicles and portable electronics.
Innovation Solution
A process for producing electrochemical cells with high active material mass loadings and thick electrodes by continuously depositing wet cathode and anode active material mixtures onto current collectors, using a quasi-solid electrolyte with high salt concentrations, and integrating these electrodes into a laminated cell structure, enabling higher volumetric capacities and energy densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional slurry coating and drying processes are used to manufacture lithium-ion batteries, then manufacturing precision and electrode quality are maintained, but electrode thickness is limited and active material mass loading is low, resulting in low volumetric energy density
Solution Approach 1:
The patent changes the physical state parameter of the electrolyte from liquid to quasi-solid gel form, enabling thick electrode construction without compromising ion transport. This parameter change allows electrode thickness to increase from conventional limits to several hundred micrometers, directly increasing active material mass loading and volumetric energy density
Solution Approach 2:
The patent incorporates the electrolyte into the electrode structure during the electrode formation process itself, rather than adding it later. The wet electrode is assembled with the gel electrolyte already present, and then dried to form the final structure with electrolyte-filled pores, preliminary establishing the ion transport pathways before cell assembly
2Reliability
If graphite-based anodes are used in lithium-ion batteries, then safety is improved compared to lithium metal, but specific capacity is limited to 372 mAh/g and recharge time is long
Solution Approach 1:
The patent uses composite anode structures combining graphite particles with gel electrolyte matrices, creating a hybrid material system that maintains the safety benefits of graphite while increasing capacity through additional lithium storage in the gel phase and reduced diffusion path lengths
Solution Approach 2:
The patent employs porous electrode structures with controlled pore sizes and distributions, allowing enhanced electrolyte penetration and shorter lithium ion diffusion paths. The porous architecture increases the effective surface area for electrochemical reactions, boosting specific capacity while maintaining structural integrity
3Volume of stationary object
If electrode thickness is increased to improve volumetric energy density, then manufacturing complexity and quality control difficulty increase
Solution Approach 1:
The gel electrolyte performs dual functions as both the ion transport medium and the binding agent holding the electrode structure together. This self-binding property eliminates the need for separate binder materials and simplifies the electrode formulation, enabling consistent quality control in thick electrodes through self-organizing gel networks
Solution Approach 2:
The patent implements continuous manufacturing processes where electrodes are formed, electrolyte is incorporated, and drying occurs in an integrated continuous line. This continuous action maintains uniform electrolyte distribution and consistent electrode properties throughout the thick electrode structure, ensuring manufacturing precision
4Weight of moving object
If overhead weight is reduced to improve gravimetric energy density, then structural integrity and component durability may be compromised
Solution Approach 1:
The patent employs thin-film current collectors and flexible separator membranes that provide sufficient mechanical strength at minimal weights. The gel electrolyte itself forms a flexible yet structurally supportive matrix that maintains cell integrity while contributing minimal overhead weight compared to traditional liquid electrolyte systems with additional protective components
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 process results in electrochemical cells with unprecedentedly high volumetric energy and power densities, reduced overhead weight and volume, and improved manufacturing efficiency, addressing the limitations of conventional lithium-ion battery technology.
Implementation Method 1
continuously depositing wet cathode and anode active material mixtures onto current collectors
Implementation Method 2
electrochemical cells with high active material mass loadings and thick electrodes
Data Source
AI summary
A process for producing an electrochemical cell, comprising: (A) continuously depositing a wet cathode active material mixture onto a surface of a cathode current collector to form a cathode electrode, wherein the wet cathode active material mixture contains 30% to 85% by volume of a cathode active material and 0% to 15% by volume of a conductive additive dispersed in a first liquid or polymer gel electrolyte; (B) continuously depositing a wet anode active material mixture onto a surface of an anode current collector to form an anode electrode, wherein the wet anode active material mixture contains an anode active material and a conductive additive dispersed in a second electrolytes; and (C) combining the cathode electrode or a portion thereof and the anode electrode or a portion thereof to form the cell; wherein the anode electrode and/or the cathode electrode has a thickness from 200 μm to 3,000 μm.