Laser Processing of Ceramic Electrolytes for Rapid Densification

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Solution Overview

Problem

Current manufacturing methods for solid-state lithium batteries face challenges such as brittleness-induced manufacturing difficulties, poor densification, lithium loss, surface contamination, and interfacial failures, which hinder the production of high-energy density batteries with stable ionic conductivity and safety.

Innovation Solution

The use of advanced laser processing techniques for laser sintering and ablation to densify ceramic electrolyte materials, remove surface contaminants, and pattern surfaces, allowing for localized heating and rapid processing without direct contact, thereby overcoming the limitations of conventional furnace sintering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If furnace sintering is used to densify ceramic electrolyte material, then densification can be achieved, but lithium loss occurs and processing time is long

Engineering Contradiction:

Improvedensification qualityVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces the conventional furnace sintering system with a laser-based processing system. The laser beam directly heats and densifies the ceramic electrolyte material without requiring prolonged high-temperature furnace exposure, thereby achieving densification while significantly reducing processing time and lithium loss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser processing system applies localized heating to specific regions of the ceramic electrolyte material rather than uniform heating of the entire sample. This localized energy input enables precise control over the densification process, achieving high-density regions where needed while minimizing overall processing time and material loss.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If furnace sintering is used to densify ceramic electrolyte material, then densification can be achieved, but lithium loss occurs

Engineering Contradiction:

Improvedensification qualityVSAvoidlithium loss

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser processing method rapidly heats and densifies the material in a short time period, skipping through the prolonged high-temperature exposure required by furnace sintering. This rapid processing minimizes the time window for lithium evaporation and loss while still achieving the necessary densification.

Inventive Principle:

Principle #21Skipping (Rushing through)

3Manufacturing precision

If mechanical polishing is used to clean surface contaminants, then surface cleanliness can be improved, but thin films cannot be processed due to brittleness

Engineering Contradiction:

Improvesurface cleanlinessVSAvoidapplicability to thin films

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces mechanical polishing with laser-based surface treatment. The laser ablates or cleans surface contaminants from the ceramic electrolyte material through localized heating and vaporization, eliminating the need for mechanical contact. This approach works effectively for thin films that would be damaged by mechanical polishing due to their brittleness and thinness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Laser processing enables efficient densification, reduces lithium loss, enhances surface cleanliness and contact, and facilitates the production of high-density, thin-film solid-state electrolytes, improving the integration and performance of solid-state lithium batteries.

Implementation Method 1

A laser may be used to heat and densify a ceramic electrolyte material

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

allowing for localized heating and rapid processing

Methodology Applied

Scientific EffectLocalized heating: Heating

Implementation Method 3

The system may be used to perform any combination of operations including cleaning, polishing, patterning, trimming, and/or marking on a ceramic electrolyte material

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11865636B2Systems and methods for laser processing of solid-state batteries

Publication Date: 2024.01.09 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

The present disclosure relates to a system for laser processing of a ceramic electrolyte material. The system may include a controller, a laser responsive to the controller for generating a beam, and a beam forming subsystem. The beam forming subsystem controls a parameter of the beam generated by the laser. The beam forming subsystem further controls the beam to provide a laser fluence sufficient to produce densification of the ceramic electrolyte material.