Electrode Assembly Coating for Stable Solid-State Battery Interfaces
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Solution Overview
Problem
Existing methods for manufacturing all-solid-state battery electrode assemblies face issues such as cracking, incomplete contact, and inter-layer mixing between the electrode and solid electrolyte layers, leading to increased resistance and reduced cell performance.
Innovation Solution
A method involving partial drying of the electrode slurry to 20-50% dryness before coating the solid electrolyte slurry, followed by controlled drying at 60-120°C, to maximize interface contact and minimize inter-layer mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the electrode layer and solid electrolyte layer are both dried to solid state before contact, then the structural stability is improved, but the contact between layers becomes insufficient and pores are formed
Solution Approach 1:
The electrode layer is dried to a semi-dried state (20-50% moisture content) before applying the solid electrolyte slurry, creating an optimal substrate that balances structural stability with contact quality. This preliminary drying action allows subsequent layers to be applied under conditions that maximize interface contact while maintaining structural integrity.
2Ease of manufacture
If a solid electrolyte slurry is coated onto a completely dried electrode layer, then the manufacturing process is simplified, but the solvent vapor causes surface irregularities on the electrolyte layer
Solution Approach 1:
The electrode layer is pre-dried to a semi-dried state (20-50% moisture content) before applying the solid electrolyte slurry. This preliminary action removes excess moisture that would otherwise evaporate during electrolyte drying and cause surface irregularities, while retaining enough moisture to maintain processability and simplify the manufacturing sequence.
3Manufacturing precision
If a wet-on-wet process is used to coat solid electrolyte slurry onto undried electrode slurry, then the contact between layers is maximized, but excessive mixing occurs at the interface causing active material delamination
Solution Approach 1:
Instead of using a fully wet-on-wet process or complete drying, the patent applies partial drying to achieve a semi-dried state (20-50% moisture content). This partial action optimizes the balance between interface contact and adhesion strength, preventing both pore formation and excessive mixing that leads to active material delamination.
4Manufacturing precision
If higher pressure is applied to transfer the solid electrolyte layer onto the electrode layer, then the contact between layers is improved, but cracking occurs in the electrode or electrolyte layers
Solution Approach 1:
The patent changes the moisture content parameter of the electrode layer from either completely dry or fully wet states to a semi-dried state (20-50% moisture content). This parameter change allows for reduced pressing pressure during electrolyte layer transfer, achieving good interface contact without causing cracking in the brittle solid 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
Enhances the endurance and performance of the electrode and cell by optimizing the contact between the electrode and solid electrolyte layers, reducing resistance and preventing surface irregularities.
Implementation Method 1
drying the electrode slurry to a degree of dryness ranging from 20% to 50% to form an incompletely dried electrode layer
Implementation Method 2
drying the solid electrolyte slurry to form a solid electrolyte layer
Data Source
AI summary
An electrode assembly is produced by partially drying an electrode slurry (20-50% dryness), then coating a solid electrolyte slurry with controlled viscosity (1,000-10,000 cP) and solids content (40-80 wt %). Both slurries are dried at 60-120° C., while the ratio of solid electrolyte slurry viscosity to electrode slurry viscosity (0.2-1.0) reduces interlayer mixing. The degree of dryness is determined by comparing residual solvent in the partially dried layer to the original slurry. This approach yields a uniform interface between the electrode and electrolyte. A corresponding method for an all-solid-state battery encloses the resulting electrode assembly, along with an anode layer, in a battery casing, ensuring enhanced interface stability.