Electrophoretic Deposition of Solid Electrolyte Thin Films
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current lithium-ion battery technologies face challenges in producing solid electrolyte thin films without defects or pores, which can lead to internal short circuits, self-discharge, and safety issues due to the limitations of existing fabrication methods, such as high costs and low productivity of vacuum deposition techniques, and the constraints on electrode materials due to the use of organic electrolytes.
Innovation Solution
The process involves electrophoretic deposition of a suspension of electrolyte material particles onto a substrate, followed by drying and consolidation through mechanical compression and/or heat treatment, using ceramic or vitroceramic compounds to create dense, pore-free solid electrolyte films that can cover three-dimensional surfaces and enhance the battery's resistance to high temperatures and oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum deposition techniques are used to produce solid electrolyte thin films, then film quality can be improved, but production costs increase and productivity decreases
Solution Approach 1:
The patent replaces the vacuum deposition mechanical system with an electrophoretic deposition system that uses electrical fields to deposit electrolyte particles from suspension. This substitution enables higher productivity while maintaining film quality, as electrophoretic deposition can be performed at atmospheric pressure and scales more efficiently for industrial production.
Solution Approach 2:
The patent changes the deposition parameters by using electrophoretic deposition at atmospheric pressure instead of vacuum conditions. This parameter change allows for faster deposition rates and improved productivity while still producing high-quality thin films with controlled thickness and uniformity.
2Power
If porous separator films are used to reduce lithium ion transport resistance, then power density can be improved, but risks of internal short circuit increase
Solution Approach 1:
The patent uses porous ceramic or vitroceramic compounds as solid electrolyte materials that provide controlled porosity for lithium ion transport. These porous materials enable high power density through efficient ion conduction while the solid structure prevents the short circuit risks associated with liquid electrolytes in porous separators.
Solution Approach 2:
The patent employs composite solid electrolyte films combining ceramic or vitroceramic particles with binding agents. This composite structure provides both the porosity needed for high power density and the structural integrity to prevent short circuits, resolving the contradiction between power and reliability.
3Ease of manufacture
If organic electrolytes are used in lithium-ion batteries, then ease of manufacture is improved, but safety issues and oxidation resistance worsen
Solution Approach 1:
The patent changes the electrolyte state from liquid organic electrolyte to solid ceramic or vitroceramic electrolyte. This parameter change eliminates the safety and oxidation issues of organic electrolytes while the solid materials can be applied using electrophoretic deposition, maintaining ease of manufacture through a streamlined single-step process.
4Productivity
If electrophoretic deposition is used to produce solid electrolyte films, then productivity and cost-effectiveness are improved, but achieving defect-free films becomes more difficult
Solution Approach 1:
The patent applies local quality control by optimizing electrophoretic deposition parameters such as voltage, time, and suspension composition to ensure uniform particle distribution and dense film formation. This localized control of deposition conditions minimizes defects like pinholes or non-uniform thickness while maintaining high productivity.
Solution Approach 2:
The replacement of vacuum deposition with electrophoretic deposition enables better control over film formation through electrical field parameters. This substitution allows for more precise control of particle arrangement and film density, reducing defects while improving production efficiency and cost-effectiveness.
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 high-quality, defect-free solid electrolyte films that improve the safety and energy storage capacity of lithium-ion batteries by preventing internal short circuits and allowing the use of higher energy materials, while also reducing production costs and increasing scalability.
Implementation Method 1
a) depositing an electrolyte thin film by electrophoresis, from a suspension of particles of electrolyte material, on said substrate and/or said previously formed anode or cathode film
Implementation Method 2
c) consolidating the electrolyte thin film obtained previously, by mechanical compression and/or heat treatment
Implementation Method 3
c) consolidating the electrolyte thin film obtained previously, by mechanical compression and/or heat treatment
Data Source
AI summary
A process for fabrication of a battery that includes providing a colloidal suspension of particles conducting lithium ions and providing two conducting substrates as battery current collectors, at least one surface of the conducting substrates being at least partially coated with one of a cathode film and an anode film, and depositing an electrolyte film by electrophoresis, from a suspension of electrolyte material particles, on at least one of said anode film, said cathode film and said conducting substrates.