Halide Solid Electrolyte Composition for Low-Temperature Synthesis

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Solution Overview

Problem

Current solid electrolyte materials for solid-state lithium batteries face challenges such as high synthesis temperatures, brittleness, safety concerns, and limited ionic conductivity, particularly in halide and sulfide materials, which hinder their mass production and application in batteries.

Innovation Solution

A halide material represented by Li3-x-fMfRE1-yMeky(Cl1-u-p-qBruFpIq)6-x+y*(k-3) is developed, incorporating at least two halide anions, alkali metals, and rare-earth elements, with improved purity, crystalline structure, and ionic conductivity, suitable for forming electrolytes in lithium batteries, using a method that includes forming ammonium-containing halides and solid-state reactions at lower temperatures to reduce impurities and enhance stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high-temperature synthesis (above 1000-1200°C) is used for oxide-based materials, then good chemical and electrochemical stability is achieved, but high synthesis costs and energy consumption occur

Engineering Contradiction:

Improveelectrochemical stabilityVSAvoidsynthesis temperature

Core Design Contradiction:

ReliabilityVSUse of energy by stationary object

Solution Approach 1:

The patent uses ammonium halide intermediates that decompose at lower temperatures to form the desired halide electrolyte material, avoiding the need for high-temperature synthesis while maintaining material stability and performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Ammonium-containing halides are used as intermediary compounds in the synthesis process, enabling the formation of stable halide electrolyte materials at lower temperatures through controlled decomposition and reaction

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If halide solid electrolytes are synthesized using high-energy ball milling-based solid-state synthesis methods, then material formation is achieved, but synthesis challenges for mass production and high costs occur due to expensive binary halide reactants and high-temperature annealing

Engineering Contradiction:

Improvesynthesis methodVSAvoidannealing temperature

Core Design Contradiction:

Ease of manufactureVSUse of energy by stationary object

Solution Approach 1:

The invention employs ammonium halide intermediates that enable synthesis at lower temperatures, eliminating the need for high-temperature annealing and high-energy ball milling while maintaining material quality and facilitating mass production

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses readily available ammonium halide compounds as temporary intermediates that decompose during the synthesis process, replacing expensive binary halide reactants and simplifying the manufacturing process

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Use of energy by moving object

If sulfide solid electrolyte materials are used, then high ionic conductivity (up to 25 mS/cm) is achieved, but safety concerns arise due to the risk of releasing toxic H2S gas when reacting with water and heat

Engineering Contradiction:

Improveionic conductivityVSAvoidH2S gas release

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent replaces sulfide materials with halide electrolyte materials that provide comparable or superior ionic conductivity while eliminating the harmful H2S gas release issue, effectively converting a harmful material class into a safe alternative

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention changes the chemical composition from sulfide-based to halide-based electrolytes, fundamentally altering the material properties to achieve high ionic conductivity without the safety hazards of H2S generation

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If high surface area sulfide solid electrolyte powders are used, then increased reactivity is achieved, but H2S risk is significantly increased due to enhanced reactivity with ambient humidity

Engineering Contradiction:

ImprovereactivityVSAvoidH2S risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces sulfide materials with halide electrolyte materials that maintain high reactivity and ionic conductivity while completely eliminating H2S generation, even in high-surface-area powder forms, by changing the fundamental chemical composition

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 new halide material exhibits enhanced ionic conductivity, electrochemical stability, and mechanical deformability, facilitating the production of high-performance solid-state lithium batteries with improved safety and reduced synthesis costs.

Implementation Method 1

enhanced ionic conductivity

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Data Source

PatentUS11848414B2Electrolyte material and methods of forming

Publication Date: 2023.12.19 SAINT GOBAIN CERAMICS & PLASTICS INC

AI summary

A solid electrolyte material can include a halide material represented by Li3-x-fMfRE1-yMeky(Cl1-u-p-qBruFpIq)6-x+y*(k-3), wherein the halide material includes at least two halide anions. The halide material can include reduced content of one or more impurity phase, including binary halide phase, oxyhalide phase, or ternary halide phase.