Electrode Assembly Void Filling for Battery Contact Stability
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Solution Overview
Problem
Lithium batteries using ceramic electrolytes face challenges such as insufficient boundary contact between ceramic electrolyte powder and electrode active materials, unstable contact due to volume changes during charge-discharge cycles, and difficulties in achieving sufficient capacity and electrical characteristics.
Innovation Solution
A manufacturing method involving the formation of an active material compact with voids, impregnation of a precursor solution for a second amorphous solid electrolyte, and heat treatment to create a second solid electrolyte within the voids, using lithium double oxides and specific electrolyte materials like Li2SiO3 and Li6SiO5, to enhance ion conductivity and battery performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If ceramic electrolyte powder is used to improve safety, then ignition or explosion risk is reduced, but boundary contact between electrolyte and electrode active material becomes insufficient
Solution Approach 1:
The patent uses porous ceramic electrolyte particles that can penetrate into the active material particles during pressing, creating extensive boundary contact areas. The porous structure allows the electrolyte to infiltrate the active material matrix, ensuring sufficient contact interfaces for ion transport while maintaining the inherent safety advantages of ceramic electrolytes
Solution Approach 2:
The patent changes the particle size parameters of the ceramic electrolyte, using fine particles with specific size ranges (e.g., 0.1-10 μm) to improve packing density and contact area. By controlling particle size distribution and pressing conditions, the patent achieves optimal boundary contact while maintaining safety
2Object-affected harmful factors
If ceramic electrolyte powder is used to improve safety, then side reactions are reduced, but contact stability during charge-discharge cycles deteriorates
Solution Approach 1:
The patent creates a composite structure where ceramic electrolyte particles are intimately mixed with active material particles at the micro-scale. This composite approach ensures stable mechanical contact during volume changes while the ceramic electrolyte layer protects against side reactions. The composite structure accommodates expansion/contraction without losing contact
3Quantity of substance
If active material thickness is increased to achieve sufficient capacity, then battery capacity is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent creates local high-concentration regions of active material within the electrode assembly, rather than uniformly increasing thickness throughout. By optimizing the local distribution and packing of active material particles with ceramic electrolyte, the patent achieves high capacity in a compact form factor, avoiding the manufacturing difficulties of thick uniform structures
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 enables the production of lithium batteries with improved safety, sufficient output, and large capacity, while minimizing the risk of ignition or explosion, and maintaining stability over charge-discharge cycles.
Implementation Method 1
impregnating a precursor solution of a second amorphous solid electrolyte conducting lithium ions with an active material compact
Implementation Method 2
performing heat treatment of the active material compact where the precursor solution is impregnated and forming a second solid electrolyte
Implementation Method 3
performing heat treatment of the active material compact where the precursor solution is impregnated and forming a second solid electrolyte in the plurality of voids
Implementation Method 4
a second amorphous solid electrolyte conducting lithium ions
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A manufacturing method of an electrode assembly includes: forming an active material compact containing a lithium double oxide and having a plurality of voids; forming a first solid electrolyte in the plurality of voids; impregnating a precursor solution of a second amorphous solid electrolyte conducting lithium ions with an active material compact in which the first solid electrolyte is formed; and performing heat treatment of the active material compact with which the precursor solution is impregnated and forming a second solid electrolyte in the plurality of voids.