Solid-state laminate electrode assemblies and battery cells thereof
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Solution Overview
Problem
Current solid-state battery technologies face challenges in producing high-quality, moisture-resistant solid electrolyte layers due to issues with sputtering targets, leading to non-uniform films and contamination, which affect the performance and reliability of lithium metal batteries.
Innovation Solution
The development of a nitrogen-rich Li-P-N thin film and a composite solid electrolyte PVD target with a layered architecture, using phosphorus nitride and lithium phosphate, to create a moisture-resistant interface and improve the mechanical integrity and purity of the films deposited, enhancing the performance of lithium metal batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sputtering targets are used to deposit solid electrolyte films, then the manufacturing process is simple, but the film quality is poor with non-uniformity, pinholes, and contamination
Solution Approach 1:
The sputtering target is segmented into multiple functional layers: a substrate layer, a buffer layer, and a solid electrolyte material layer. This segmentation allows each layer to be optimized independently for its specific function, resulting in high-quality pinhole-free films while managing fabrication complexity through modular design
Solution Approach 2:
A buffer layer is deposited preliminarily on the substrate before depositing the solid electrolyte material layer. This preliminary action prevents direct contact between the solid electrolyte and substrate, eliminating pinhole formation and improving film uniformity without requiring complex target fabrication
2Manufacturing precision
If high-purity target material is used to produce smooth pinhole-free films, then film quality improves, but manufacturing cost and complexity increase due to difficult fabrication
Solution Approach 1:
The target structure is divided into a buffer layer and a solid electrolyte material layer, allowing the buffer layer to be fabricated with standard processes while the material layer achieves high purity through controlled deposition, balancing film smoothness with manufacturing ease
Solution Approach 2:
The buffer layer acts as an intermediary between the substrate and the solid electrolyte material layer, providing a clean interface that enables smooth film deposition without requiring the entire target to be fabricated with extreme purity, thus simplifying manufacturing
3Reliability
If conventional solid electrolyte layers are used, then the battery structure is simple, but moisture resistance is poor leading to adverse reactions with ambient moisture
Solution Approach 1:
The solid electrolyte layer is segmented into multiple functional layers including a buffer layer and a solid electrolyte material layer, where each layer provides specific protection against moisture while maintaining overall structural simplicity for battery integration
Solution Approach 2:
The solid electrolyte layer uses composite structure with buffer layer and solid electrolyte material layer, combining materials with complementary properties to achieve superior moisture resistance while managing structural complexity through functional differentiation
4Manufacturing precision
If proper buffer layer is deposited to prevent pinholes, then film uniformity improves, but deposition time and process complexity increase
Solution Approach 1:
The buffer layer is deposited to a thickness that is sufficient to prevent pinhole formation and ensure film uniformity, but not excessively thick to avoid unnecessary deposition time, optimizing the balance between film quality and process efficiency
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 solution results in high-quality, moisture-resistant films that improve the electrical properties and stability of the Li/solid electrolyte interface, enabling the production of high-energy density rechargeable lithium metal batteries with enhanced performance and reliability.
Implementation Method 1
The quality of the film depends on the quality of the sputtering target material... films deposited by sputtering methods
Implementation Method 2
The quality of the film depends on the quality of the sputtering target material... in particular, high purity and excellent mechanical integrity is especially important for producing smooth pinhole free films
Data Source
AI summary
Solid-state laminate electrode assemblies and various methods for making the solid-state laminate electrode assemblies involve a lithium metal layer reactively bonded to a lithium ion conducting sulfide glass layer. During manufacture, highly reactive surfaces of the lithium metal layer and the lithium ion conducting sulfide glass layer are maintained in its substantially unpassivated state until they have been reactively bonded. An intermediary solid electrolyte structure has a Li ion conducting solid electrolyte layer covered with a thin as-deposited lithium phosphorus nitride film. A surface protected solid electrolyte having a solid electrolyte layer having a first major surface that is covered by a composite protective film, the composite protective film having a lithium phosphorus material component and a phosphorus nitride material component. A physical vapor deposition target for the deposition of a composite protective film, the target having a compacted composite material target having a mosaic structure.