Composite Solid Electrolyte Layering for Uniform Ceramic Dispersion

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Solution Overview

Problem

Conventional composite solid electrolytes face challenges in achieving improved ionic conductivity due to non-uniform distribution of inorganic particles, which limits their performance in lithium-ion batteries.

Innovation Solution

A method for preparing a composite solid electrolyte involves forming a first composite layer by mixing a first polymer with cross-linkable functional groups and a ceramic compound, sintering to create a ceramic ion conductor layer, and then coating this layer with a second polymer and lithium salt, all performed in a continuous process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional solution casting method is used to prepare composite solid electrolyte, then the manufacturing process is simple, but the inorganic particles are non-uniformly distributed resulting in poor ionic conductivity

Engineering Contradiction:

Improveuniformity of inorganic particle distributionVSAvoidcomplexity of preparation process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The preparation process is divided into multiple sequential steps: (1) mixing polymer and inorganic material to form first composite layer, (2) sintering to form ceramic ion conductor layer, and (3) coating with second polymer and lithium salt. This segmentation allows each step to optimize for its specific function, achieving uniform particle distribution while maintaining manufacturability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inorganic particles are pre-dispersed in the polymer matrix during the first composite layer formation before sintering. This preliminary dispersion action ensures uniform distribution is achieved before the final electrolyte structure is completed, preventing aggregation that would occur in conventional methods.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If high temperature drying is used in solution casting, then the electrolyte film is formed, but the non-uniform distribution of inorganic particles persists limiting ionic conductivity improvement

Engineering Contradiction:

Improveionic conductivity of composite solid electrolyteVSAvoidease of preparing uniform composite solid electrolyte

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The conventional mechanical mixing and solution casting approach is replaced with a multi-step process including sintering and sequential coating. This substitution allows thermal processing (sintering) to achieve uniform particle distribution and bonding, followed by controlled coating for electrolyte formation, thereby improving ionic conductivity while maintaining ease of manufacture.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The process utilizes parameter changes including temperature control during sintering to achieve optimal particle distribution and bonding. The sequential coating parameters (composition, thickness, drying conditions) are optimized to ensure uniform electrolyte formation without disrupting the underlying uniform particle distribution.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional batch processing is used, then the preparation method is straightforward, but mass production and continuous manufacturing are difficult to achieve

Engineering Contradiction:

Improvecontinuous manufacturing capabilityVSAvoidcomplexity of continuous processing system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The preparation method is designed as a continuous process where the first composite layer is continuously formed, sintered, and then continuously coated with the second polymer and lithium salt solution. This continuity of useful action enables mass production while the modular nature of the sequential steps keeps the system complexity manageable.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The first composite layer is prepared and sintered in advance to create a stable ceramic ion conductor substrate before the final electrolyte coating is applied. This preliminary action allows the continuous manufacturing process to proceed efficiently with each step building on the completed previous step, enhancing productivity without excessive complexity.

Inventive Principle:

Principle #10Preliminary action

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 method enhances the ionic conductivity of the composite solid electrolyte by ensuring uniform dispersion of ceramic particles, thereby improving the performance of lithium-ion batteries and enabling mass production.

Implementation Method 1

a first polymer having a cross-linkable functional group and a ceramic compound

Methodology Applied

Scientific EffectCross-linking: Chemical Bonding

Implementation Method 2

preparing a ceramic ion conductor layer by sintering the first composite layer

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 3

coating the ceramic ion conductor layer with a composition containing a second polymer and a lithium salt

Methodology Applied

Scientific EffectDissolution: Solvation

Data Source

PatentUS20250183356A1Method for manufacturing composite solid electrolyte

Publication Date: 2025.06.05 LG ENERGY SOLUTION LTD

AI summary

A method for preparing a composite solid electrolyte is characterized by forming a battery material having high ionic conductivity, and the method is capable being carried out as a continuous process, and used mass production.