Dry-Compressed Solid-State Lithium-Ion Cell Lamination
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Solution Overview
Problem
Solid state electrolytes in lithium-ion batteries face challenges such as low conductivity, limited stability, and poor mechanical properties, which hinder their scalability and integration into high-capacity devices due to the need for high-temperature sintering and brittle film formation.
Innovation Solution
The method involves compressing dry mixtures of electrode and electrolyte materials to form films, including calendering processes, which enables the creation of solid-state electrodes and electrolytes with improved mechanical strength and conductivity, using materials like Li3PS4 glass ceramic and optional air-stabilizing dopants, allowing for scalable production of solid-state batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature sintering is used to consolidate solid state electrolyte films, then interfacial impedance is managed and films are consolidated, but the films become brittle and production is limited to low capacity devices or small disks
Solution Approach 1:
The patent changes the temperature parameter from high-temperature sintering to room temperature or low-temperature processing. The dry compression process achieves film consolidation without thermal treatment, producing flexible films that can be scaled to large areas while maintaining low interfacial impedance and avoiding brittleness
Solution Approach 2:
The patent replaces the thermal consolidation mechanism (sintering) with a mechanical compression mechanism (dry compression/calendering). This substitution allows film consolidation through applied pressure rather than heat, resulting in mechanically robust yet flexible films suitable for high-capacity devices
2Reliability
If conventional sintering processes are used for solid state electrolytes, then films are consolidated, but production scalability is limited to low capacity devices
Solution Approach 1:
The patent changes the processing temperature parameter from high to low/room temperature, enabling scalable production. The dry compression process can be continuously applied to large areas without the limitations of batch sintering, allowing production of large-format batteries for high-capacity applications
Solution Approach 2:
The patent uses a layer-by-layer dry compression approach where electrolyte and electrode materials are sequentially compressed to form integrated films. This segmented process enables continuous manufacturing and scaling to large device capacities while maintaining film quality
3Object-affected harmful factors
If solid state electrolytes are used in lithium ion batteries, then safety advantages are provided by reducing thermal runaway risk, but conductivity and mechanical properties are insufficient for practical applications
Solution Approach 1:
The patent employs composite materials consisting of solid state electrolyte particles combined with conductive additives and binding agents in a dry mixture. This composite structure maintains the safety benefits of solid electrolytes while enhancing ionic conductivity through the conductive network and improving mechanical properties through the binding matrix
Solution Approach 2:
The patent applies different material compositions to different regions: the solid state electrolyte particles provide safety and ionic conduction pathways, conductive additives enhance local conductivity, and binding agents provide mechanical integrity. This local optimization of material properties achieves both safety and performance
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 results in solid-state batteries with enhanced ionic conductivity, mechanical strength, and stability, enabling high-volume production of lithium-ion batteries with improved performance and cycle life, comparable to conventional liquid electrolyte cells.
Implementation Method 1
compressing an electrode dry mixture to form an electrode film
Implementation Method 2
compressing an electrode dry mixture to form an electrode film... compressing an electrolyte dry mixture to form a stand-alone solid-state electrolyte film
Data Source
AI summary
Methods for preparing an electrode may include compressing an electrode dry mixture comprising an active material and an electrolyte material to form an electrode film. An electrolyte dry mixture or a stand-alone solid-state electrolyte film is compressed against a surface of the electrode film to form a laminate of an electrolyte layer and the electrode film. The electrolyte dry mixture may include the electrolyte material. Compressing the electrode dry mixture may include calendering the electrode dry mixture. Compressing the electrolyte dry mixture or stand-alone electrolyte film may be accomplished also by calendering. The electrolyte material may include a glass ceramic and, optionally, an air-stabilizing dopant. The glass ceramic may include Li3PS4. Thus, the electrodes may include a composite cathode and a solid-state electrolyte layer. The methods may be applicable for a solvent-free process to form electrodes and electrochemical cells and batteries including the electrodes.