Method for reducing an air gap at the interface between an anode and a solid electrolyte of a solid-state battery cell

Abstract

Aspects of the disclosure include tempo-spatial manipulation of ultrasonics (TSMU) for the fabrication of solid-state batteries and solid-state batteries fabricated using the same. An exemplary vehicle includes an electric motor and a battery pack electrically coupled to the electric motor. The battery pack includes a solid-state battery cell with an anode having a major surface, a solid electrolyte in direct contact with the anode, and an interface between the anode and the solid electrolyte.The interface is subjected to TSMU comprising a first ultrasonic phase at an emission angle parallel to the main surface of the anode, a second ultrasonic phase at an emission angle orthogonal to the main surface of the anode, and a third ultrasonic phase at an emission angle parallel to the main surface of the anode, thereby reducing an air gap between the anode and the solid electrolyte at the interface.

Description

INITIATIONThe present invention relates to the manufacture of battery cells and, more particularly, to a method for reducing an air gap at the interface between an anode and a solid electrolyte of an all solid state battery cell.High voltage electrical systems are increasingly used to power the on-board functions of both mobile and stationary systems. For example, in automobiles, demand for lower fuel consumption and emissions has led to the development of advanced electric vehicles (EVs). Electric vehicles rely on rechargeable energy storage (RESS) systems, which typically include one or more high voltage battery packs and an electric powertrain that transfers power from the battery to the wheels. Depending on the power requirement of a respective application, battery packs may comprise any number of battery modules interconnected with one another. Each battery module comprises a series of conductively coupled electrochemical cells. The battery pack is configured to provide a direct current (DC) output voltage of a level suitable for powering a coupled electrical and / or mechanical load (e.g., an electric motor).The lithium ion battery (LIB) has developed into one of the most common chemical battery compositions for these and other applications. A typical lithium ion battery consists of three major components: an anode, often made of graphite, a cathode, often made of lithium cobalt oxide (LiCoO 2), lithium manganese oxide (LiMn 2 O 4) or lithium iron phosphate (LiFePO 4) and a liquid electrolyte, typically a lithium salt dissolved in a solvent such as ethylene carbonate and dimethyl carbonate. The electrolyte allows the lithium ions to move between the anode and cathode during charging and discharging.Recently, solid-state batteries have proven to be a potential next generation replacement for lithium ion batteries, as are known in the manner described in the publications JP 2018-170 112 A and U.S. Pat. No. 11 380 938 B2. In an all-solid-state battery, the conventional liquid electrolyte is replaced with an all-solid material (e.g., a solid electrolyte (SE)). The solid electrolyte may take various forms, including ceramic, polymers, or a combination of both. Solid state batteries offer various advantages over liquid electrolyte based batteries, such as relatively higher energy density, longer cycle life, greater operating temperature range, and greater flexibility in design because they are inherently thinner and lighter.SUMMARYAccording to the invention, there is provided a method of reducing an air gap at the interface between an anode and a solid electrolyte of an all solid state battery cell, which method is characterized by the features of claim 1.Further described is a vehicle including an electric motor and a battery pack electrically coupled to the electric motor. The battery pack includes an all-solid-state battery cell having an anode having a main surface, a solid electrolyte in direct contact with the anode, and an interface between the anode and the solid electrolyte. The interface is subjected to a TSMU including a first ultrasonic phase at an emission angle parallel to the main surface of the anode, a second ultrasonic phase at an emission angle orthogonal to the main surface of the anode, and a third ultrasonic phase at an emission angle parallel to the main surface of the anode, thereby reducing an air gap between the anode and the solid electrolyte at the interface.In addition to one or more of the features described herein, in some embodiments, the first ultrasonic phase includes a lateral ultrasonic phase, the second ultrasonic phase includes a vertical ultrasonic phase, and the third ultrasonic phase includes a lateral ultrasonic phase.In some embodiments, the first ultrasound phase, the second ultrasound phase, and the third ultrasound phase occur sequentially.In some embodiments, the TSMU is terminated while the anode and solid electrolyte are pressurized to less than 20 MPa.In some embodiments, the TSMU is terminated with an ultrasonic power between 20 W and 70 W.In some embodiments, the TSMU is completed within a processing time of between 30 seconds and 5 minutes.In some embodiments, the TSMU includes galvanostatic cycling.Also described is an all-solid-state battery cell including an anode having a main surface, a solid electrolyte in direct contact with the anode, and an interface between the anode and the solid electrolyte. The interface is subjected to a TSMU including a first ultrasonic phase at an emission angle parallel to the main surface of the anode, a second ultrasonic phase at an emission angle orthogonal to the main surface of the anode, and a third ultrasonic phase at an emission angle parallel to the main surface of the anode, thereby reducing an air gap between the anode and the solid electrolyte at the interface.In some embodiments, the first ultrasound phase includes a lateral ultrasound phase, the second ultrasound phase includes a vertical ultrasound phase, and the third ultrasound phase includes a lateral ultrasound phase.In some embodiments, the first ultrasound phase, the second ultrasound phase, and the third ultrasound phase occur sequentially.In some embodiments, the TSMU is terminated while the anode and solid electrolyte are pressurized to less than 20 MPa.In some embodiments, the TSMU is terminated with an ultrasonic power between 20 W and 70 W.In some embodiments, the TSMU is completed within a processing time of between 30 seconds and 5 minutes.In some embodiments, the TSMU includes galvanostatic cycling.In some embodiments of the method according to the invention, the first ultrasonic phase comprises a lateral ultrasonic phase, the second ultrasonic phase comprises a vertical ultrasonic phase and the third ultrasonic phase comprises a lateral ultrasonic phase.In some embodiments of the method according to the invention, the first ultrasound phase, the second ultrasound phase and the third ultrasound phase take place one after the other, whereby a temporal-spatial ultrasound manipulation (TSMU) is defined.In some embodiments of the method of the invention, the TSMU is terminated while the component is pressurized to less than 20 MPa.In some embodiments of the method according to the invention, the TSMU is terminated with an ultrasonic power of between 20 W and 70 W.In some embodiments of the method according to the invention, the TSMU is terminated within a processing time of between 30 seconds and 5 minutes.The above features and advantages, as well as other features and advantages of the invention, will be readily apparent from the following detailed description taken in conjunction with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGSOther features, advantages, and details are included, by way of example only, in the following detailed description, which relates to the drawings. FIG. 1 is a vehicle configured according to one or more embodiments; FIG. 2 is an example of an anode-electrolyte interface before and after time-spatial ultrasonic (TSMU) manipulation, according to one or more embodiments; FIG. 3A is an example of an ultrasonic control system for applying TSMU to a battery component, according to one or more embodiments; FIG. 3B is a detailed view of a portion of the ultrasonic control system of FIG. 3A, in accordance with one or more embodiments; FIG. 3C is a detailed view of a portion of the ultrasonic control system of FIG. 3B, in accordance with one or more embodiments; FIG. 4 is an example of a 3-phase lateral-vertical-lateral TSMU ultrasound treatment cycle according to one or more embodiments; FIG. 5 is a computer system according to one or more embodiments; and FIG. 6 is a flow diagram according to one or more embodiments.DETAILED DESCRIPTIONThe following description is merely exemplary in nature. It should be understood that throughout the drawings, corresponding reference numerals designate like or corresponding parts and features.With the increasing demand for energy storage systems with higher energy density, faster charging, and longer life, driven in part by the increasing spread of electric vehicles, significant challenges are placed on the materials used in the battery cells. The research and development efforts are continually directed toward identifying novel materials and fabrication techniques that can meet the increasing demands on battery cells and other energy storage systems. For example, solid state batteries are increasingly being studied as a potential next generation replacement for conventional batteries (e.g., lithium ion batteries such as LFP batteries). In an all-solid state battery, the liquid electrolyte is replaced with a solid electrolyte and the anode is typically made of an alkali metal, often lithium metal, although other alkali metals are also possible (e.g., Na, K, Zn and Mg).However, there are still challenges in the development and production of solid-state batteries with solid electrolytes. In particular, in the manufacture of an all-solid-state battery, the solid electrolyte is usually sintered with a relatively rough surface at the anode / cathode, so that the contact loss at the interface between the electrolyte and the anode or cathode can be considerable. This results in increased interfacial resistance (e.g., a reduction in ion transport effects), and the non-uniform deposition / detachment of the metal anode or cathode at the discontinuous contact interface results in the growth of metal dendrites during the electrochemical cycling process and ultimately a reduction in battery performance.This invention introduces the use of time-space ultrasonic manipulation for the manufacture of all-solid state batteries. Instead of relying on high pressure calendering in the lamination of anode, electrolyte and cathode, ultrasonic vibrations are employed to improve the uniformity of the metal flatness at the interface between the electrolyte and the anode / cathode. Without wishing to be bound by theory, it is believed that the introduction of ultrasonic sound while the anode-electrolyte-cathode stack is maintained under reduced pressure (as compared to the relatively high pressures encountered with conventional pressure rollers) causes the electrode metal to soften and transiently transition to a flowable state with improved planar flux, thereby allowing the electrode metal to migrate into any air gaps between the electrolyte and the anode / cathode. This process can be considered a kind of ultrasonic coating, and thus contact losses can be minimized. In particular, time-spatial ultrasound (TSMU) manipulation is introduced to maximize the propagating energy for the ultrasound coating while reducing the possibility of electrolyte cracking. In some embodiments, the TSMU process includes galvanostatic cycling between three phases: a first lateral ultrasound treatment phase, a vertical ultrasound treatment phase, and a second lateral ultrasound treatment phase.Utilizing time-spatial ultrasound manipulation according to one or more embodiments provides several technical advantages over existing battery fabrication techniques. In particular, the manufacturing process described herein may be used at lower pressures (e.g., less than 20 MPa) than conventional calendering processes (e.g., 100 or even 150 MPa), thereby reducing stresses within the battery pack. Moreover, it has been found that cycling between the phases of lateral, vertical and lateral ultrasound treatment increases the bonding index between the electrolyte and the anode / cathode, while avoiding the formation of cracks in the electrolyte that occur with constant vertical ultrasound treatment. Further advantages are possible. For example, TSMU has been shown to significantly retard battery shortage, and ultrasonic vibration treatments have been shown to occur without a significant temperature rise (less than 50 degrees Celsius, e.g., 40-45 degrees Celsius), thereby reducing the risk of side reactions.A vehicle according to an exemplary embodiment is generally designated 100 in FIG. 1. The vehicle 100 is shown in the form of an automobile having a body 102. The body 102 includes a passenger compartment 104 in which a steering wheel, front seats, and rear seats (not separately indicated) are disposed. A number of components are disposed in the body 102, including, for example, an electric motor 106 (shown by projection below the front hood). The electric motor 106 is shown for ease of illustration and discussion only.The electric motor 106 is powered via a battery pack 108 (shown by projection near the rear of the vehicle 100). The battery pack 108 is shown for ease of illustration and discussion only. Although the present invention is discussed primarily in the context of a battery pack 108 configured for the electric motor 106 of the vehicle 100, the aspects described herein may be similarly incorporated into any system (vehicle, building, or otherwise) having one or more energy storage systems (e.g., one or more battery packs or modules).As discussed in more detail herein, the battery pack 108 includes one or more battery cells and / or pouch batteries having a new battery design that uses TSMU to reduce contact resistance between the anode (or cathode) and an electrolyte. An example of an anode-electrolyte interface before and after a TSMU treatment is shown in FIG. 2. An example of an ultrasonic control system for applying TSMU to a battery component is shown in FIGS. 3A, 3B, and 3C. An example of a 3-phase lateral-vertical-lateral TSMU ultrasound treatment cycle is shown in FIG. 4.FIG. 2 shows an example of an anode electrolyte interface 200 before and after a TSMU treatment 202, according to one or more embodiments. The anode electrolyte interface 200 may be integrated into a battery cell of a battery pack (e.g., the battery pack 108 in FIG. 1 ). While FIG. 2 is discussed primarily with respect to an anode electrolyte interface, it should be appreciated that a TSMU treatment may be similarly applied to a cathode electrolyte interface (omitted for simplicity). In addition, a single TSMU treatment may be performed simultaneously on the anode electrolyte interface and on the cathode electrolyte interface.As shown in FIG. 2, prior to TSMU treatment 202, anode-electrolyte interface 200 includes a number of gaps 204 (also referred to as air gaps) between anode 206 and solid electrolyte 208. In this configuration, the direct contact between the anode 206 and the solid electrolyte 208 is incomplete, resulting in a reduction in ion migration since the ions must travel around the gaps 204.As further shown in FIG. 2, the anode electrolyte interface 200 has been greatly improved after the TSMU treatment 202 because the gaps 204 have been removed completely (or within the tool boundaries, such as reducing the gaps 204 by more than 95%). In other words, the direct contact between the anode 206 and the solid electrolyte 208 is greatly improved compared to the anode-electrolyte interface 200 prior to the TSMU treatment 202. TSMU treatment 202 is discussed in more detail in connection with FIG. 4.FIG. 3A illustrates an example of an ultrasonic control system 300 for applying TSMU to a battery component 302, according to one or more embodiments. FIG. 3B illustrates a detailed view of a portion 304 of the ultrasound control system 300 of FIG. 3A. FIG. 3C illustrates a detailed view of a portion 306 of the ultrasound control system 300 of FIG. 3B.As shown in FIG. 3A, the battery component 302 of the ultrasonic control system 300 is disposed between a force sensor 308 and an ultrasonic control unit 310. In some embodiments, the ultrasound controller 310 includes or is communicatively coupled to a processor (see FIG. 5 ) to control a TSMU treatment (e.g., the TSMU treatment 202 of FIG. 2 ). TSMU treatment is discussed in more detail in connection with Figure 4.In some embodiments, a compression device 312 is placed on the ultrasound controller 310. In some embodiments, the compression device 312 compresses the battery component 302 to a particular TSMU pressure, for example, 5 to 15 MPa. The compression device 312 may comprise, for example, a hydraulic plate or a piston, a pressure roller or a pair of pressure rollers and / or a pneumatic actuator, without this being intended to represent a particular limitation. In some embodiments, the ultrasound control system 300 includes a positive terminal 314 (V+) and a negative terminal 316 (V-). The positive terminal 314 and the negative terminal 316 are arranged to conduct current through the battery component 302 as it is pressurized by the compression device 312. In some embodiments, the ultrasonic control unit 310 directs a constant current density of 0.05 to 10 mA / cm 2, e.g., 0.1 mA / cm 2, via the positive terminal 314 and the negative terminal 316 via the battery component 302 (i.e., the ultrasonic control unit 310 and / or the ultrasonic control system 300 may be configured for galvanostatic cycling). Other waveforms are also possible, such as pulse waveforms.As shown in FIG. 3B, the ultrasound control system 300 may also include a positive conductor 318 and a negative conductor 320 connected to the positive terminal 314 and the negative terminal 316, respectively. In some embodiments, the positive conductor 318 is electrically coupled to a cathode current collector 322 (see FIG. 3C ) of the battery component 302 and the negative conductor 320 is electrically coupled to an anode current collector 324 (see FIG. 3C ) of the battery component 302. In some embodiments, the battery component 302 is secured between the positive terminal 314 and the negative terminal 316 via one or more terminals 326 and / or a screw 328 (as shown), although other configurations for securing the battery component 302 are also possible.As shown in FIG. 3C, the battery component 302 may include, from top to bottom, the anode current collector 324, an anode 330, a solid electrolyte 332, a cathode 334, and the cathode current collector 322. The anode current collector 324 and the cathode current collector 322 may be made of sheets or foils of conductive metal. The cathode current collector 322 may be made of, for example, aluminum foil, stainless steel, and / or titanium foil. Other materials are possible, such as semimetals (e.g. tin, graphite) and alloys of metals and / or semimetals. In some embodiments, the cathode current collector 322 is made of aluminum foil. The anode current collector 324 may include, for example, a copper foil and / or one or more graphene layers.Anode 330 and cathode 334 are not intended to be particularly limited, and may include, for example, various anode or cathode materials, such as activated carbon powder, nickel manganese cobalt oxide (NMC), lithium iron phosphate (LFP), nickel cobalt aluminum oxide (NCA), nickel cobalt manganese aluminum oxide (NCMA), lithium manganese iron phosphate (LMFP), lithium and manganese rich (LMR), lithium manganese oxide (LiMn 2 O 4, LMO), graphite, silicon, silicon-graphite composites, tin, tin, and the like, Tin oxide (SnO 2), lithium titanate (Li 4 Ti 5 O 12, LTO), sulfur and lithium-sulfur compounds (Li-S), lithium metal (Li), and / or lithium alloys such as lithium antimony (Li-Sb), lithium aluminum (Li-Al), and lithium germanium (Li-Ge). In some embodiments, anode 330 is an alkali metal anode, such as a lithium metal (Li) anode and / or a sodium metal (Na) anode. In some embodiments, cathode 334 is a transition metal oxide such as lithium cobalt oxide (LiCoO 2) and / or rhombohedral Na 3 V 2( PO 4)3( referred to as NVP).The solid electrolyte 332 is not particularly limited, and may include, for example, various ceramics and polymers such as polyethylene oxide-based polymers and lithium phosphorus oxynitride (LiPON), sulfide-based solid electrolytes such as lithium germanium phosphorus sulfide (Li 10 GeP 2 S 12), oxide-based solid electrolytes such as lithium lanthanum zirconium oxide (Li 7 La 3 Zr 2 O 12, IIzo) and lithium lanthanum zirconium tantalum oxide (Li 6,4 La 3 Zr 1,4 Ta 0,6 O 12), NASICON-type solid electrolytes (e.g., Li 1,3 Al 0,3 Ti 1,7( PO 4)3) and sodium-based composites such as Na 3 Zr2Si2PO12(referred to as NZSP).FIG. 4 illustrates an example of a 3-phase lateral-vertical-lateral (LVL) TSMU ultrasound treatment cycle 400 (hereinafter TSMU 400), according to one or more embodiments. As shown in FIG. 4, the TSMU 400 begins at step 1 (denoted by the virtualized 1). Step 1 illustrates the initial (incoming) provision of a battery component, such as the battery component 302 of FIGS. 3A, 3B, and 3C. The interfacial resistance (Ω) is relatively high at this time, e.g., about 790 Ω, with a resistance per unit area of 1388 Ω / cm 2.As further shown in FIG. 4, the battery component undergoes a first lateral phase ultrasonic treatment (e.g., by the ultrasonic control system 300 of FIG. 3A ) between step 1 and step 2 (characterized by the stylet 2). As used herein, a "lateral phase ultrasonic treatment" refers to the application of ultrasound at a delivery angle parallel to a major surface 336 of the anode of the battery component (see FIG. 3C ). In some embodiments, the first lateral phase ultrasonic treatment occurs when the battery component is pressurized to less than 20 MPa, for example, 5 to 15 MPa. In some embodiments, the first lateral phase ultrasonic treatment occurs at an ultrasonic power between 20 W and 70 W. In some embodiments, the first lateral phase ultrasonic treatment results in an interfacial temperature of less than 60 C, for example between 40 C and 45 C. In some embodiments, the first lateral phase ultrasonic treatment occurs with a processing time of between 30 seconds and 5 minutes. In some embodiments, the first lateral phase ultrasonic treatment occurs at a frequency between 50 kHz (at 70 W) and 200 kHz (at 20 W).Step 2 depicts the battery component after the first lateral phase ultrasonic treatment. The interfacial resistance (Ω) is significantly lowered, e.g., to 250 Ω, with a resistance per unit area of 220 Ω / cm 2.As further shown in FIG. 4, the battery component undergoes vertical phase ultrasonic treatment (e.g., by the ultrasonic control system 300 of FIG. 3A ) between step 2 and step 3 (characterized by the stylet 3). As used herein, "vertical phase ultrasonic treatment" refers to the application of ultrasound at an output angle orthogonal to the major surface 336 (see FIG. 3C ). In some embodiments, the vertical phase ultrasonic treatment occurs when the battery component is pressurized to less than 20 MPa, for example, 5 to 15 MPa. In some embodiments, the vertical phase ultrasonic treatment occurs at an ultrasonic power between 20 W and 70 W. In some embodiments, the vertical phase ultrasonic treatment results in an interfacial temperature of less than 60 DEG C., for example between 40 DEG C. and 45 DEG C. In some embodiments, the vertical phase ultrasonic treatment occurs with a processing time of between 30 seconds and 5 minutes. In some embodiments, the vertical phase ultrasonic treatment occurs at a frequency between 50 kHz (at 70 W) and 200 kHz (at 20 W).Step 3 represents the battery component after the vertical phase ultrasonic treatment. The interfacial resistance (Ω) was further lowered, e.g., to 150 Ω, with a resistance per unit area of 70 Ω / cm 2.As further shown in FIG. 4, between step 3 and step 4 (characterized by the stylet 4), the battery component is subjected to a second lateral phase ultrasonic treatment (e.g., by the ultrasonic control system 300 of FIG. 3A ). In some embodiments, the second lateral phase ultrasonic treatment occurs when the battery component is pressurized to less than 20 MPa, for example, 5 to 15 MPa. In some embodiments, the second lateral phase ultrasonic treatment occurs at an ultrasonic power between 20 W and 70 W. In some embodiments, the second lateral phase ultrasonic treatment results in an interfacial temperature of less than 60 C, for example between 40 C and 45 C. In some embodiments, the second lateral phase ultrasonic treatment occurs with a processing time of between 30 seconds and 5 minutes. In some embodiments, the second lateral phase ultrasonic treatment occurs at a frequency between 50 kHz (at 70 W) and 200 kHz (at 20 W).Step 4 shows the battery component after the second lateral phase ultrasonic treatment. The interfacial resistance (Ω) was further lowered, e.g., to 130 Ω, with a resistance per unit area of 68 Ω / cm 2.It can be seen in FIG. 4 that the application of TSMU 400 reduces the interfacial resistance per unit area of thousands of ohms per unit area (e.g., 1388 Ω / cm 2) to several tens of ohms per unit area (e.g., 68 Ω / cm 2). This is particularly superior to a constant vertical ultrasonic treatment which has been found to be inherently limited to interface resistances of hundreds of ohms per unit area, since attempting to achieve lower resistances results in cracks in the solid electrolyte which short the underlying device. In other words, even if resistances of less than 100 ohms per unit area could be theoretically achieved with a constant vertical ultrasound treatment, these results are not really attainable due to short-circuit effects. Without wishing to be bound by theory, it has been found that the 3-phase lateral-vertical lateral ultrasound treatment cycle 400 (i.e., the insertion of a vertical phase between two lateral phase ultrasound treatments) achieves resistances of below 100, while maintaining the structural integrity of the solid electrolyte (avoiding cracks).FIG. 5 illustrates aspects of an embodiment of a computer system 500 that may perform various aspects of the embodiments described herein. In some embodiments, the computer system 500 may be integrated as a system (e.g., the ultrasound controller 310 of FIG. 3A ) for manufacturing a battery component (e.g., the battery component 302 of FIG. 3A ) of a battery pack (e.g., the battery pack 108 of FIG. 1 ). The computer system 500 includes at least one processing device 502 that generally includes one or more processors to perform a variety of functions, such as setting one or more parameters of a TSMU process as described herein (e.g., ultrasonic power, ultrasonic processing time and / or frequency, ultrasonic delivery angle, etc.).Components of computer system 500 include processing device 502 (such as one or more processors or processing units), system memory 504, and a bus 506 that couples various system components including system memory 504 to processing device 502. System memory 504 may include a plurality of media readable by the computer system. These media may be any available media that can be accessed by the processing device 502, both volatile and nonvolatile media, and removable and non-removable media.System memory 504 includes, for example, non-volatile memory 508 such as a hard disk, and may also include volatile memory 510 such as random access memory (RAM) and / or cache memory. Computer system 500 may further include other removable / non-removable, volatile / non-volatile computer system storage media.System memory 504 may include at least one program product having a set of program modules (e.g., at least one) configured to perform the functions of the embodiments described herein. For example, system memory 504 stores various program modules that generally perform the functions and / or methods of the embodiments described herein. One or more modules 512, 514 may be included to perform functions related to monitoring and / or controlling the battery pack 108, such as determining one or more current cell temperatures, a current state of charge of the battery pack 108, and / or any cell of the battery pack 108, a duration of charging, a charging current, and / or a charging voltage, etc. The computer system 500 is not limited thereto, as other modules may also be included depending on the desired functionality of the vehicle 100. As used herein, the term module refers to processing circuitry that may include an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group), and memory that executes one or more software or firmware programs, combinatorial logic circuitry, and / or other suitable components that provide the described function. For example, the module or modules may be configured via software, hardware, and / or firmware to stop the charging operation and / or otherwise isolate one or more cells of a battery pack of the vehicle 100.The processing device 502 may also be configured to communicate with one or more external devices 516, such as a keyboard, a pointing device, and / or other devices (e.g., a network card, a modem, a vehicle ECU, etc.) that enable the processing device 502 to communicate with one or more other computing devices. Communication with various devices may be via input / output (I / O) interfaces 518 and 520.The processing device 502 may also communicate with one or more networks 522, such as a local area network (LAN), a general wide area network (WAN), a bus network, and / or a public network (e.g., the Internet), via a network adapter 524. In some embodiments, network adapter 524 is or includes an optical network adapter for communication over an optical network. It should be understood that other hardware and / or software components may also be used in conjunction with computer system 500, although not shown. Examples include microcode, device drivers, redundant processing units, external disk arrays, RAID systems, data archive systems, etc.Referring now to FIG. 6, a flowchart 600 for the manufacture of all-solid state batteries using TSMU is generally shown, according to an embodiment. The flow chart 600 is described with reference to FIGS. 1-5 and may include further steps not shown in FIG. 6. While the blocks shown in FIG. 6 are shown in a particular order, they may be reordered, subdivided, and / or combined.At block 602, the method includes receiving a component that includes an anode, a solid electrolyte, and an interface between the anode and the solid electrolyte. The anode has a major surface.At block 604, the method includes exposing the interface to a first ultrasonic phase at an emission angle parallel to the major surface of the anode.At block 606, the method includes exposing the interface to a second ultrasonic phase at an emission angle orthogonal to the major surface of the anode.At block 608, the method includes exposing the interface to a third ultrasonic phase at an emission angle parallel to the major surface of the anode.In some embodiments, the first ultrasound phase includes a lateral ultrasound phase, the second ultrasound phase includes a vertical ultrasound phase, and the third ultrasound phase includes a lateral ultrasound phase.In some embodiments, the first ultrasound phase, the second ultrasound phase, and the third ultrasound phase occur sequentially, defining a temporal-spatial ultrasound manipulation (TSMU).In some embodiments, the TSMU is terminated while the component is pressurized to less than 20 MPa. In some embodiments, the applied pressure at the TSMU is constant. In some embodiments, the applied pressure is between 5 MPa and 15 MPa.In some embodiments, the TSMU is terminated with an ultrasonic power between 20 W and 70 W.In some embodiments, the TSMU is completed within a processing time of between 30 seconds and 5 minutes.In some embodiments, the TSMU includes galvanostatic cycling. In some embodiments, the TSMU includes galvanostatic cycling with a constant current density of 0.1 mA / cm 2.

Claims

A method for reducing an air gap at the interface (200) between an anode (206, 330) and a solid electrolyte (208, 306) of an all solid state battery cell (302), comprising: - providing an all solid state battery cell (302) comprising an anode (206, 330) having a major surface (336), a solid electrolyte (208, 306), and an interface (200) between the anode (206, 330) and the solid electrolyte (208, 306); - exposing the interface (200) to a first ultrasonic phase at an emission angle parallel to the major surface (336) of the anode (206, 330); - exposing the interface (200) to a second ultrasonic phase at an emission angle orthogonal to the major surface (336) of the anode (206, 330); and - exposing the interface (200) to a third ultrasonic phase at an emission angle parallel to the main surface (336) of the anode (206, 330).The method of claim 1, wherein the first ultrasound phase comprises a lateral ultrasound phase, the second ultrasound phase comprises a vertical ultrasound phase, and the third ultrasound phase comprises a lateral ultrasound phase.The method of claim 1, wherein the first ultrasound phase, the second ultrasound phase, and the third ultrasound phase occur sequentially, thereby defining a temporal-spatial ultrasound manipulation (TSMU).The method of claim 3, wherein the TSMU is terminated while the anode (206, 330) and the solid electrolyte (208, 306) are pressurized to less than 20 MPa.The method of claim 3, wherein the TSMU is terminated with an ultrasonic power between 20 W and 70 W.The method of claim 3, wherein the TSMU is completed within a processing time of between 30 seconds and 5 minutes.The method of claim 3, wherein the TSMU comprises galvanostatic cycling.

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