Interfacial Bonding Layer for Anode-Free Solid-State Battery Dendrites

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Solution Overview

Problem

Lithium ion batteries face dendrite formation during charging, which can lead to short circuits, overheating, and potential fire due to lithium plating on the anode surface, causing safety concerns.

Innovation Solution

An anode-free solid-state battery design incorporating a lithium gel separator layer and an anti-dendrite layer, along with an interfacial bonding layer, to inhibit dendrite growth and enhance electrical connectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If lithium ions plate onto the anode surface during charging, then lithium storage capacity increases, but dendrite formation occurs leading to short circuits and safety hazards

Engineering Contradiction:
Improvelithium storage capacityVSAvoidbattery safety
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

A gel separator layer is introduced as an intermediary between the cathode and anode. This gel separator acts as a physical barrier that prevents direct contact between electrodes while allowing lithium ion transport, thereby eliminating dendrite-induced short circuits while maintaining lithium storage capacity

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

A thin anti-dendrite layer is deposited on the anode surface to create a protective interface. This thin film structure physically constrains dendrite growth while maintaining ionic conductivity, allowing lithium ions to deposit uniformly without forming harmful dendritic structures

Inventive Principle:
Principle #30Flexible shells and thin films

2Reliability

If an anti-dendrite layer is added to prevent dendrite formation, then battery safety improves, but electrical connectivity between the anode and lithium deposits decreases

Engineering Contradiction:
Improvedendrite preventionVSAvoidelectrical connectivity
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The anti-dendrite layer is constructed as a composite material combining polymer matrix with conductive fillers (such as carbon black or metal particles). This composite structure provides both the physical barrier needed to prevent dendrites and the electrical conductivity required to maintain efficient electron transport between the anode and lithium deposits

Inventive Principle:
Principle #40Composite materials

3Reliability

If a gel separator layer is introduced to prevent short circuits, then battery safety increases, but battery impedance increases reducing performance

Engineering Contradiction:
Improveshort circuit preventionVSAvoidbattery impedance
Core Design Contradiction:
ReliabilityVSPower

Solution Approach 1:

The gel separator's physical and chemical parameters are optimized by adjusting polymer concentration, crosslinking density, and pore structure. These parameter changes reduce ionic transport resistance while maintaining the separator's safety functions, thereby lowering overall battery impedance without compromising short circuit prevention

Inventive Principle:
Principle #35Parameter changes

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 design effectively reduces dendrite formation, maintaining battery integrity and safety by promoting even lithium deposition across the anode surface, thereby decreasing impedance and enhancing performance.

Implementation Method 1

The interfacial bonding layer may increase an amount of electrical connectivity between the anode current collector layer and lithium deposited on the interfacial bonding layer during charging of the anode-free solid-state battery

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

The anti-dendrite layer may discourage dendrite formation

Methodology Applied
Scientific EffectDendrite inhibition:

Implementation Method 3

During charging of a lithium ion battery, lithium ions migrate from battery's cathode to the battery's anode through a separator located between the cathode and anode

Methodology Applied
Scientific EffectIon migration:

Implementation Method 4

Through a process called intercalation, lithium ions become inserted into the material functioning as the anode

Methodology Applied
Scientific EffectIntercalation: Absorption (physical)

Data Source

PatentUS12412901B2Interfacial bonding layer for an anode-free solid-state-battery
Publication Date: 2025.09.09 TERAWATT TECHNOLOGY INC
  • US12412901B2 patent drawing
  • US12412901B2 patent drawing
  • US12412901B2 patent drawing

AI summary

An anode-free solid-state battery may include a cathode layer; an anode current collector layer; and a separator layer between the cathode layer and the anode current collector layer. The battery can further include an anti-dendrite layer located between the separator layer and the anode current collector layer. The battery further includes an interfacial bonding layer located between the anti-dendrite layer and the anode current collector layer. The interfacial bonding layer increases an amount of electrical connectivity between the anode current collector layer. A first amount of adhesion between the interfacial bonding layer and the anode current collector layer can be greater than a second amount of adhesion between the anti-dendrite layer and the interfacial bonding layer.