All-Solid Multilayer Battery Electrophoretic Deposition
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Solution Overview
Problem
Conventional lithium-ion batteries face challenges with internal short-circuits, thermal runaway, and poor performance under extreme temperatures due to porosity and organic materials in their electrolytes, limiting their application in miniaturization and temperature stability.
Innovation Solution
A method for producing all-solid lithium-ion batteries using electrophoresis to deposit anode, electrolyte, and cathode layers, with a lithium ion-conducting Ms bonding material layer to facilitate stacking and ensure good contact between layers, allowing for the creation of a compact, multilayer battery assembly without high-temperature processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lithium-ion batteries use porous electrodes with liquid electrolytes, then the battery can achieve good ion transport, but the battery suffers from internal short-circuits, thermal runaway, and poor performance under extreme temperatures
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid to solid, and transforms the porous electrode structure into a dense thin-film structure. This parameter change eliminates the harmful effects of liquid electrolytes (thermal runaway, internal short-circuits) while maintaining ion transport capability through the solid electrolyte layer
Solution Approach 2:
The patent replaces porous materials with dense thin-film structures. The electrophoretic deposition technique produces compact, non-porous electrode layers that eliminate the porosity-related issues of conventional batteries, including internal short-circuits and thermal instability
2Reliability
If thin-film electrodes are used to prevent resistance, then the battery achieves better ion transport, but the manufacturing process becomes complex and requires high-temperature processing
Solution Approach 1:
The patent replaces high-temperature thermal processing with electrophoretic deposition, a low-temperature electrical field-based technique. This substitution enables thin-film electrode manufacturing without the complex high-temperature equipment and processes required by conventional methods
Solution Approach 2:
The patent introduces an intermediary liquid medium containing suspended particles that enables low-temperature deposition. The electrophoretic process uses this liquid intermediary to transport and deposit solid particles forming thin films, avoiding the need for direct high-temperature processing
3Quantity of substance
If all-solid thin-film structure is used to maximize active material density, then energy density increases, but the contact between stacked layers becomes insufficient leading to poor electrical connection
Solution Approach 1:
The patent applies periodic thermal treatment cycles to the stacked layers. These controlled heating cycles enhance the contact between adjacent layers by promoting diffusion and bonding, ensuring good electrical connection while maintaining the high active material density of the thin-film structure
Solution Approach 2:
The patent utilizes phase transitions during thermal treatment to improve layer contact. The controlled heating induces phase changes in the materials at layer interfaces, facilitating better bonding and electrical connection between the dense thin-film layers
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 approach eliminates internal short-circuits and thermal issues, enhances energy density, and enables batteries to operate effectively across a wide temperature range without the risks of combustion or self-discharge, while maintaining high power and energy densities.
Implementation Method 1
each of said three layers being deposited by electrophoresis
Implementation Method 2
a thermal treatment and/or mechanical compression promoting contact between said two layers stacked face-to-face
Data Source
AI summary
A method for producing an all-solid multilayer battery, and an all-solid multilayer battery. The all-solid multilayer battery may be produced by depositing, by electrophoresis without any binder, at least one anode layer, at least one electrolyte layer, and at least one cathode layer. The at least one electrolyte layer, and the at least one cathode layer are obtained from a colloidal suspension containing nanoparticles that are not agglomerated with each other to create clusters and remain isolated from each other. A layer of Ms bonding material is then deposited on a surface of the at least one electrolyte layer. Next, two layers from the at least one dense anode layer, the at least one dense electrolyte layer, and the at least one dense cathode layer, are stacked face-to-face to obtain the all-solid multilayer battery having an assembly of a plurality of elementary cells connected with one another in parallel.