Electrospray Electrospinning Composite Layer Formation for Solid-State Batteries
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Solution Overview
Problem
The commercialization of solid-state batteries is hindered by manufacturing challenges such as air and moisture sensitivity, mechanical fragility of solid electrolytes, and high interfacial resistance between electrode and electrolyte layers, as well as expensive and complex manufacturing methods.
Innovation Solution
A method involving electrospraying and electrospinning techniques to deposit solid cathode, electrolyte, and anode layers directly on top of each other, using a rotating cylinder and electric fields to form composite layers with high density, enabling scalable and affordable production of all-solid-state batteries in ambient conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional liquid electrolytes are used in lithium ion batteries, then manufacturing is easier and cost is lower, but safety is poor due to electrolyte flammability and thermal instability
Solution Approach 1:
The patent changes the physical state parameter of the electrolyte from liquid to solid, eliminating flammability and thermal instability while maintaining ionic conductivity through careful selection of solid electrolyte materials and optimization of their composition and structure
Solution Approach 2:
The patent employs composite structures combining solid electrolytes with electrode materials, using multiple layers and interfaces to achieve both safety improvements and manufacturability through standardized assembly processes
2Reliability
If solid-state electrolytes are used to improve safety and energy density, then battery performance is improved, but interfacial resistance between electrolyte and electrodes increases
Solution Approach 1:
The patent applies different surface treatments and interface engineering to specific regions where electrolyte-electrode contacts occur, optimizing local interfacial properties to reduce resistance while maintaining bulk solid electrolyte benefits
Solution Approach 2:
The patent introduces intermediary layers or coating materials at the electrolyte-electrode interfaces to facilitate better contact and reduce interfacial resistance, acting as mediators between the solid electrolyte and electrode materials
3Quantity of substance
If solid electrolytes are used to achieve higher energy density, then battery capacity is improved, but mechanical fragility increases
Solution Approach 1:
The patent employs thin-film solid electrolyte structures that maintain high energy density while reducing mechanical fragility through controlled thickness and support structures, creating flexible yet dense energy storage layers
Solution Approach 2:
The patent creates composite structures where solid electrolytes are combined with mechanically robust materials to form hybrid systems that maintain high energy density while improving overall mechanical strength and durability
4Ease of manufacture
If conventional manufacturing methods are used for solid-state batteries, then production is simpler, but large impedance at solid-solid interfaces hinders performance
Solution Approach 1:
The patent merges the electrolyte and electrode fabrication into integrated processes, creating monolithic or near-monolithic structures that eliminate traditional solid-solid interfaces and reduce impedance while maintaining manufacturing simplicity
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 reduces interfacial resistance, allows for the use of various materials, and facilitates the production of high-density, scalable, and cost-effective all-solid-state batteries with improved performance and energy density.
Implementation Method 1
the first spray nozzle is configured to apply onto the substrate a first plurality of at least one of particles or droplets from the first fluid
Implementation Method 2
the first fiber nozzle is configured to apply onto the substrate a first fiber from the second fluid
Implementation Method 3
the first plurality of particles or droplets and the first fiber combine to form a first composite layer on the substrate
Data Source
AI summary
An aspect of the present disclosure is a system that includes a first deposition system that includes a first cylinder having a first outer surface configured to hold a first substrate, a first spray nozzle configured to receive at least a first fluid, and a first fiber nozzle configured to receive at least a second fluid, where the first spray nozzle is configured to operate at a first voltage, the first fiber nozzle is configured to operate at a second voltage, the first cylinder is configured to be electrically connected to ground, the first spray nozzle is configured to apply onto the substrate a first plurality of at least one of particles or droplets from the first fluid, the first fiber nozzle is configured to apply onto the substrate a first fiber from the second fluid, and the first plurality of particles or droplets and the first fiber combine to form a first composite layer on the substrate.