Liquid-Phase Deposition of Thin Films on Solid-State Electrolytes
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Solution Overview
Problem
Traditional methods for coating solid-state electrolytes in rechargeable batteries face challenges such as ionic impedance, inadequate wetting, and formation of secondary phases due to interfacial issues, and are limited by high costs and inefficiencies in vapor-phase atomic layer deposition processes.
Innovation Solution
A liquid-phase deposition method is employed to form artificial solid-electrolyte interphase (SEI) layers on substrates, using a series of liquid solutions and rinsing steps to achieve precise control over film thickness and conformality, leveraging solvation energy for efficient heating and improved safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional vapor-phase atomic layer deposition (ALD) is used to coat solid-state electrolytes, then conformal thin films with precise thickness can be achieved, but the process suffers from high costs, low materials utilization, and manufacturing inefficiencies
Solution Approach 1:
The patent changes the phase parameter of the deposition process from vapor-phase to liquid-phase. This fundamental parameter change enables the use of solution-based precursors that can be applied at lower temperatures and with better materials utilization, while maintaining the self-limiting surface reaction mechanism that ensures precise film thickness control
Solution Approach 2:
The patent replaces the vacuum-based vapor delivery system with liquid-phase solution delivery using hydraulic principles. The liquid precursor solutions are pumped through the system and applied to substrates, enabling continuous processing and better materials efficiency compared to vacuum-based vapor-phase ALD
2Manufacturing precision
If vapor-phase ALD is used for coating, then precise monolayer-by-monolayer growth control is achieved, but precursor condensation occurs at high temperatures leading to loss of growth control and unpredictable film thickness
Solution Approach 1:
The patent changes the temperature parameter by using liquid-phase precursors that react at lower temperatures. The solution-based approach eliminates the need for high-temperature vaporization, preventing precursor condensation issues while maintaining self-limiting surface reactions for precise monolayer growth control
Solution Approach 2:
The patent replaces the thermal vaporization mechanism with a solution-based chemical reaction mechanism. Instead of relying on thermal energy to vaporize precursors, the system uses dissolved precursors that react directly on the substrate surface, eliminating temperature-related condensation problems
3Ease of manufacture
If solid-state electrolytes are paired with standard rechargeable battery electrodes, then battery assembly is simplified, but ionic impedance increases and wetting is inadequate
Solution Approach 1:
The patent applies preliminary action by coating the solid-state electrolyte surface with a thin film layer before electrode assembly. This pre-coating modifies the surface properties to improve wetting and reduce ionic impedance, allowing simplified assembly procedures to produce reliable batteries with good ionic conductivity
Solution Approach 2:
The patent introduces an intermediary thin film layer between the solid-state electrolyte and the electrode. This intermediary layer mediates the interface by improving ionic transport and wetting properties, reconciling the simplicity of direct assembly with the need for reliable ionic conductivity
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
This method enables the production of high-quality, conformal thin films on both continuous and discrete substrates, enhancing battery performance by reducing impedance and improving materials utilization, while being more scalable and cost-effective than traditional vapor-phase deposition techniques.
Implementation Method 1
A liquid-phase deposition method is employed to form artificial solid-electrolyte interphase (SEI) layers on substrates, using a series of liquid solutions and rinsing steps
Implementation Method 2
Substrate surfaces react with impinging vapor to produce precisely one self-limiting, surface-saturating monolayer of adsorbed metalorganic
Data Source
AI summary
Methods, systems, and compositions for the solution-phase deposition of thin films comprising one or more artificial solid-electrolyte interphase (SEI) layers. The thin films can be coated onto the surface of porous components of electrochemical devices, such as solid-state electrolytes employed in rechargeable batteries. The methods and systems provided herein involve exposing the component to be coated to different liquid reagents in sequential processing steps, with optional intervening rinsing and drying steps. Processing may occur in a single reaction chamber or multiple reaction chambers.