Lithium Boride Electrolyte Deposition for Solid State Batteries
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Solution Overview
Problem
The existing methods for manufacturing solid state lithium batteries require controlled vacuum environments due to the reactivity of electrolyte and electrode materials with moisture, limiting the scalability and cost-effectiveness of thin film lithium battery production.
Innovation Solution
The use of combustion chemical vapor deposition (CCVD) to deposit dense, amorphous lithium boride (LiBO2) electrolytes in an open air environment, allowing for the fabrication of intercalated lithium batteries without the need for controlled atmospheres, and enabling a continuous rolling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum deposition methods are used to deposit LiPON electrolyte, then ionic conductivity is improved, but manufacturing complexity and cost increase due to vacuum environment requirements
Solution Approach 1:
The patent changes the chemical composition parameters of the electrolyte from LiPON (lithium phosphorus oxynitride) to LiBO2 (lithium metaborate), which fundamentally alters the material's stability characteristics. LiBO2 maintains adequate ionic conductivity while being stable in ambient atmospheric conditions, eliminating the need for vacuum deposition equipment and complex moisture-controlled manufacturing environments.
2Reliability
If metallic lithium is used as negative electrode, then open circuit voltage is improved, but safety and handling difficulty worsen due to reactivity with moisture
Solution Approach 1:
The patent introduces LiBO2 electrolyte as an intermediary protective layer between the metallic lithium negative electrode and the ambient atmosphere. This electrolyte layer acts as a barrier that prevents direct contact between moisture and reactive lithium metal, thereby maintaining the high open circuit voltage benefits of metallic lithium while eliminating safety hazards associated with its reactivity.
3Reliability
If amorphous thin film electrolyte is used, then ionic conductivity is improved, but fabrication difficulty increases due to limited deposition methods
Solution Approach 1:
The patent changes the material composition from LiPON to LiBO2, which fundamentally alters the deposition requirements. LiBO2 can be deposited as amorphous thin films using simple solution-based methods or conventional sputtering, eliminating the need for complex nitrogen-containing plasma processes required for LiPON. This material substitution maintains amorphous structure benefits for ionic conductivity while dramatically simplifying fabrication.
4Manufacturing precision
If vacuum or controlled environment processes are used, then manufacturing precision is improved, but productivity decreases due to batch processing requirements
Solution Approach 1:
The patent changes the manufacturing environment parameter from vacuum to ambient atmosphere, which enables continuous rolling production processes. Solution-based deposition methods can be applied continuously to moving substrates in ambient conditions, eliminating the need to repeatedly pump down and vent vacuum chambers for each batch, thereby maintaining film quality while dramatically increasing production throughput.
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 approach reduces fabrication costs and increases process speed by enabling the production of solid state lithium batteries in ambient conditions, potentially lowering upfront plant costs and improving output efficiency.
Implementation Method 1
The use of combustion chemical vapor deposition (CCVD) to deposit dense, amorphous lithium boride (LiBO2) electrolytes in an open air environment
Implementation Method 2
combustion chemical vapor deposition (CCVD)
Data Source
AI summary
A method for fabricating intercalated lithium batteries in open air deposits a thin dense layer of amorphous solid-state lithium boride electrolyte directly onto a negative electrode via flame spray pyrolysis. In one embodiment, the negative electrode is attached to a prefabricated positive electrode via hot pressing (embossing), thus forming an intercalated lithium battery. The method significantly improves upon current methods of fabricating thin film solid state batteries by permitting fabrication without the aid of a controlled environment, thereby allowing for significantly cheaper fabrication than prior batch methods.