Foamed Ion Conductive Layer with Hygroscopic Electrolyte Porosity

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Solution Overview

Problem

Current solid-state lithium batteries face challenges in achieving improved performance and safety due to limitations in the development of effective ion conductive layers for solid-state electrolytes, particularly in terms of ion conductivity and structural integrity.

Innovation Solution

A solid ion conductive layer is developed, comprising a foamed matrix with a hygroscopic electrolyte material, such as halide-based or sulfide-based materials, which includes a porous structure and a composite layer with electron conductive materials, allowing for controlled porosity and thickness to enhance ion conductivity and compatibility with battery components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If solid-state electrolytes are used to improve battery performance and safety, then energy density and recharging speed are improved, but ion conductivity and structural integrity are insufficient

Engineering Contradiction:

Improverecharging speedVSAvoidion conductivity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs porous structures within the solid-state electrolyte layer to enhance ion conductivity. The porous architecture provides additional pathways for ion transport, effectively increasing the overall ion conductivity of the solid-state electrolyte while maintaining its solid-state properties, thereby resolving the contradiction between improved recharging speed and sufficient ion conductivity

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent utilizes composite material structures combining different electrolyte materials with complementary properties. By integrating multiple materials with distinct advantages, the composite electrolyte achieves both high ion conductivity and structural integrity, enabling faster recharging while maintaining reliability

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If solid-state electrolytes are used to enable lithium metal anode, then energy density is improved, but structural integrity and safety are compromised

Engineering Contradiction:

Improveenergy densityVSAvoidstructural integrity

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent modifies physical and chemical parameters of the solid-state electrolyte, including composition ratios, processing conditions, and structural characteristics. These parameter changes optimize the electrolyte's mechanical strength and structural integrity while preserving its ability to support lithium metal anode, thus achieving high energy density without compromising safety

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent incorporates protective structural features and material selections that preemptively address potential structural failures. By designing the electrolyte with inherent structural reinforcement and failure-mitigation characteristics before assembly, the system maintains structural integrity under the high energy density conditions enabled by lithium metal anode

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS11757099B2Ion conductive layer and methods of forming

Publication Date: 2023.09.12 SAINT GOBAIN CERAMICS & PLASTICS INC

AI summary

A solid ion conductive layer can include a foamed matrix and an electrolyte material including a hygroscopic material. In an embodiment, the electrolyte material can include a halide-based material, a sulfide-based material, or any combination thereof. In another embodiment, the solid ion conductive layer can include total porosity of at least 30 vol % for a total volume of the solid ion conductive layer.