Lithium Oxysulfide Composite Electrode Protection

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Solution Overview

Problem

Existing electrochemical cell protective layers face challenges in maintaining minimal defects and mechanical stability, leading to electrolyte penetration and failure due to brittleness and swelling issues with ceramic materials and polymers.

Innovation Solution

A composite structure comprising a flexible, low-swelling polymeric separator with an ion conductor layer, such as lithium oxysulfide, is used to inhibit electrolyte interaction with electrodes, enhancing adhesion and mechanical stability through surface treatment and vacuum deposition processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ceramic materials are used as protective layers, then electrolyte interaction is inhibited, but mechanical stability deteriorates due to brittleness and swelling

Engineering Contradiction:

Improveelectrolyte interaction inhibitionVSAvoidmechanical stability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies composite materials by combining ceramic coating layers with flexible substrate materials to create a protective structure that exhibits both the electrolyte-blocking properties of ceramics and the mechanical flexibility of the substrate, thereby resolving the contradiction between electrolyte interaction inhibition and mechanical stability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses flexible thin film substrates as the base structure for the protective layer, allowing the ceramic coating to be applied on a mechanically stable and flexible foundation that prevents brittleness while maintaining electrolyte interaction inhibition

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If polymer separator is used, then mechanical stability is maintained, but electrolyte penetration occurs leading to electrode failure

Engineering Contradiction:

Improvemechanical stabilityVSAvoidelectrolyte penetration resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent creates a composite structure where a ceramic coating layer is applied on top of a polymer separator, combining the mechanical stability of the polymer with the electrolyte penetration resistance of the ceramic layer

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by coating only the surface of the polymer separator with ceramic material, maintaining the bulk mechanical properties of the polymer while adding electrolyte resistance at the critical interface with the electrolyte

Inventive Principle:

Principle #3Local quality

3Reliability

If protective layer is applied to inhibit electrolyte interaction, then electrode protection is improved, but adhesion and mechanical stability deteriorate

Engineering Contradiction:

Improveelectrode protectionVSAvoidadhesion

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Inventive Principle:

Principle #30Flexible shells and thin films

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 composite structure effectively prevents electrolyte interaction and mechanical failure, improving the durability and performance of electrochemical cells by maintaining the integrity of the ion conductor layer and separator during cycling and pressurized conditions.

Implementation Method 1

The ion conductor layer has a lithium-ion conductivity of at least at least 10−6 S/cm

Methodology Applied

Scientific EffectIon conduction: Conduction (electrical)

Implementation Method 2

the separator has a bulk electronic resistivity of at least about 104 Ohm-meters

Methodology Applied

Scientific EffectElectronic resistivity: Electrical Resistance

Implementation Method 3

The ion-conducting material can inhibit interaction between the protected electrode and an electrolyte

Methodology Applied

Scientific EffectPhysical barrier: Physical Containment

Data Source

PatentUS11367892B2Electrode protection using a composite comprising an electrolyte-inhibiting ion conductor

Publication Date: 2022.06.21 SION POWER CORP

AI summary

Composite structures including an ion-conducting material and a polymeric material (e.g., a separator) to protect electrodes are generally described. The ion-conducting material may be in the form of a layer that is bonded to a polymeric separator. The ion-conducting material may comprise a lithium oxysulfide having a lithium-ion conductivity of at least at least 10−6 S/cm.