Anode-Supported Solid-State Separator for Thin Cells Without Edge Shorting
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Solution Overview
Problem
Existing lithium-ion battery separators are thick and self-supporting, limiting energy density, and anode-supported designs face compatibility issues with casting processes and edge shorting due to cathode overhang.
Innovation Solution
An anode-supported electrolyte separator with compositions like yLi2S·(100-y-x)P2S5·xP2O5, Li10MP2S12, or argyrodite, thickness ranging from 1 to 100 micrometers, and an overhang design to prevent edge shorting, integrated with anode current collectors and cathodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the separator thickness is reduced to improve energy density, then the battery cell energy density increases, but the separator loses its self-supporting ability
Solution Approach 1:
The separator is merged with the anode by depositing the separator directly onto the anode surface, creating an integrated anode-supported separator structure. This eliminates the need for a separate self-supporting structure, allowing the separator to be made extremely thin while maintaining structural integrity through the anode support.
Solution Approach 2:
The separator is implemented as an extremely thin film (1-100 micrometers) that would normally lack self-supporting ability, but this thin film is deposited onto the anode which provides the necessary mechanical support, enabling the use of ultra-thin separator material to maximize energy density.
2Quantity of substance
If the separator is deposited directly onto the anode to reduce thickness, then energy density improves, but compatibility with casting process deteriorates due to lithium metal anode reactivity
Solution Approach 1:
The invention changes the chemical composition parameters of the separator material to specific lithium phosphorus sulfus (LPs) based compositions that are chemically compatible with lithium metal anodes, enabling the separator to be deposited directly onto the anode without reactive incompatibility issues that would prevent manufacturing.
3Ease of manufacture
If the anode area is increased to accommodate the separator, then the separator can be deposited on the anode, but edge shorting occurs due to anode overhang contacting the cathode
Solution Approach 1:
The separator acts as an intermediary barrier that extends beyond the cathode edges (overhang) to prevent direct contact between the anode and cathode at the edges. This overhanging separator portion serves as a protective mediator that blocks potential shorting paths while allowing the anode to maintain its larger area for effective separator deposition.
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
Enhances battery energy density and prevents shorting by ensuring the anode-supported electrolyte separator covers a larger area than the cathode, maintaining electrical insulation and lithium ion transport.
Implementation Method 1
a solid material that is an ionic conductor, particularly a lithium ionic conductor, that also blocks the passage of electrons
Data Source
AI summary
An anode electrode for a battery cell, a battery cell, and a method of forming an anode supported electrolyte separator. The anode electrode includes an anode current collector including a first surface and an anode supported electrolyte separator disposed on the first surface. The anode supported electrolyte separator includes at least one electrolyte selected from the following compositions: a) yLi2S·(100-y-x)P2S5·xP2O5 wherein y is in the range of 70 mole percent to 80 mole percent and x is in the range of 1 mole percent to 10 mole percent, b) Li10MP2S12 wherein M is at least one of Si, Ge, and Sn, and c) argyrodite. In addition, the anode supported electrolyte separator exhibits a thickness in the range of 1 micrometers to 100 micrometers.