Solution-Processed Garnet Solid-State Electrolyte Film
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Solution Overview
Problem
Current methods for manufacturing garnet-type solid-state lithium-ion conductors are not scalable or economically viable for large-scale production, limiting the use of garnet-type oxides as electrolytes in lithium batteries due to difficulties in processing and high costs.
Innovation Solution
A method involving a precursor composition of lithium, lanthanum, and zirconium compounds, applied to a substrate and heat-treated between 500°C to 1000°C, to form a thin-film solid-state electrolyte with controlled thickness and morphology, suitable for scalable production and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to manufacture garnet-type solid-state electrolytes, then the electrolytes can achieve desirable lithium-ion conductivity, but the manufacturing process is not scalable and has high costs
Solution Approach 1:
The patent replaces conventional mechanical processing methods (such as ball milling, pressing, and sintering) with a solution-based chemical deposition approach. The electrolyte is formed by applying a precursor solution to a substrate, which then undergoes thermal treatment to convert the precursor compounds into the desired garnet-type oxide structure. This substitution enables scalable manufacturing while maintaining lithium-ion conductivity.
Solution Approach 2:
The patent utilizes thermal treatment at controlled temperatures (typically 500-1000°C) to transform the precursor film into the active solid-state electrolyte. By controlling parameters such as treatment temperature, time, and atmosphere, the method achieves desirable lithium-ion conductivity and phase purity, enabling scalable production of high-performance electrolytes.
2Stability of the object's composition
If conventional processing methods are used, then the electrolyte structure can be formed, but the processing complexity and cost increase
Solution Approach 1:
The patent divides the electrolyte formation process into distinct stages: (1) preparation of precursor compounds containing the necessary metal elements, (2) formation of a precursor film through solution deposition, and (3) thermal treatment to convert the precursor into the active electrolyte phase. This segmentation simplifies the overall process by breaking down complex conventional methods into manageable, scalable steps.
Solution Approach 2:
The patent introduces a precursor solution as an intermediary medium that facilitates electrolyte formation. The precursor contains metal compounds dissolved or suspended in a solvent, which can be easily applied to substrates using conventional coating techniques. After deposition, the precursor undergoes thermal decomposition and reaction to form the desired garnet-type oxide structure, simplifying the manufacturing process while ensuring proper electrolyte formation.
3Volume of moving object
If thin-film form factor is achieved, then the electrolyte can be integrated into batteries, but the manufacturing method must be scalable
Solution Approach 1:
The patent replaces mechanical thin-film formation methods (such as physical vapor deposition or mechanical exfoliation) with a solution-based deposition approach. The precursor solution is applied to the substrate using scalable techniques such as spin coating, dip coating, or spray coating, followed by thermal treatment to form the thin-film electrolyte. This approach enables precise thickness control while maintaining scalability for industrial production.
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
The method produces solid-state electrolytes with desirable conductivity and reduced defect content, enabling scalable and cost-effective production of garnet-type solid-state lithium-ion conductors for lithium batteries.
Implementation Method 1
heat-treating the precursor film at a temperature of 500° C. to 1000° C. to manufacture the solid-state electrolyte
Data Source
AI summary
A method of manufacturing a solid-state electrolyte, the method including: providing a substrate; providing a precursor composition including a compound including a compound including lithium, a compound including lanthanum, and a compound including zirconium, and a solvent; disposing the precursor composition on the substrate to provide a coated substrate; treating the coated substrate at a temperature between −40° C. and 25° C. to form a precursor film on the substrate; and heat-treating the precursor film at a temperature of 500° C. to 1000° C. to manufacture the solid-state electrolyte, wherein the solid-state electrolyte includes Li(7-x)Alx/3La3Zr2O12 wherein 0≤x≤1, and wherein the solid-state electrolyte in the form of a film having a thickness of 5 nanometers to 1000 micrometers.