Glass Preform Casting for Dendrite-Resistant Li-Ion Separators
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Solution Overview
Problem
There is a need for high-performance lithium battery cells and components, particularly for secondary batteries with high energy density, that are resistant to lithium dendrite formation and can be manufactured in a cost-effective and scalable manner.
Innovation Solution
A standalone lithium ion-conductive sulfide solid electrolyte in the form of a freestanding inorganic vitreous sheet, made from sulfur-based glass, providing high lithium ion conductivity while being resistant to lithium dendrite initiation and propagation, and is manufacturable in a scalable and cost-effective way for use in lithium battery cells and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional liquid electrolytes or polymer electrolytes are used, then ease of manufacture is improved, but lithium dendrite resistance deteriorates
Solution Approach 1:
The patent changes the physical state parameter of the electrolyte from liquid or polymer to inorganic solid (glass), which fundamentally alters the material properties to achieve both high dendrite resistance and manufacturability through established glass forming processes
Solution Approach 2:
The patent uses composite glass compositions containing multiple oxides (e.g., B2O3, SiO2, P2O5, Li2O) to achieve optimal balance between dendrite resistance, ionic conductivity, and processability, combining the benefits of different material phases
2Object-affected harmful factors
If inorganic solid electrolytes are used, then lithium dendrite resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex multi-step ceramic processing (sintering, polishing, sealing) with a simplified glass forming process that uses melting and casting, eliminating the need for high-precision mechanical operations while achieving dense, defect-free electrolytes
Solution Approach 2:
The patent employs inert or controlled atmosphere processing during glass formation to prevent unwanted chemical reactions and maintain material purity, simplifying the manufacturing environment compared to reactive ceramic processing
3Ease of manufacture
If glass forming processes are used, then manufacturing cost is reduced, but control over microstructure decreases
Solution Approach 1:
The patent carefully controls compositional parameters (oxide ratios, Li2O content) and thermal parameters (cooling rate, annealing temperature) during glass formation to achieve precise control over the amorphous microstructure and ionic conductivity while maintaining cost-effective processing
Solution Approach 2:
The patent creates localized structural features within the glass matrix through compositional variations, such as modifying specific regions to enhance ionic pathways or dendrite resistance, achieving microstructural precision without complex global processing
4Reliability
If high lithium ion conductivity is achieved, then battery performance is improved, but sensitivity to surface flaws increases
Solution Approach 1:
The patent performs preliminary surface treatments during glass formation, such as fire polishing or coating, to eliminate surface flaws and dendrite initiation sites before the electrolyte is assembled into the battery, preventing future performance degradation
Solution Approach 2:
The patent incorporates surface-modifying additives or coating materials in the glass composition that preferentially segregate to the surface during forming, creating a flaw-resistant surface layer that maintains high bulk ionic conductivity while suppressing dendrite initiation
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 sulfide solid electrolyte sheet offers high lithium ion conductivity and resistance to lithium dendrites, enabling safe and efficient operation of lithium metal secondary battery cells, with the ability to be scaled and manufactured cost-effectively for various battery applications.
Implementation Method 1
highly conductive of Li ions, and, in various embodiments, the solid electrolyte sheet is devoid of continuous interconnected microscopic pathways
Implementation Method 2
a continuous vitreous solid electrolyte sheet of Li ion conducting sulfur-based glass
Data Source
AI summary
Manufacturing methods for making a substantially rectangular and flat glass preform for manufacturing a Li ion conducting glass separator can involve drawing the preform to a thin sheet and may involve one or more of slumping, rolling or casting the glass within a frame that defines a space filling region and therewith the shape and size of the preform. The thickness of the rectangular flat preform so formed may be about 2 mm or less. The frame may be slotted having a back surface and widthwise wall portion that define the height and width of the space filling region. The flat backing surface and surfaces of the widthwise wall portions are defined may be coated by a material that is inert in direct contact with the heated glass material, such as gold.