Lithium Salt-Ceramic Composite Low-Temperature Sintering
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Solution Overview
Problem
The development of lithium metal-based batteries is limited by safety concerns, short cycling capability, and low Columbic efficiency due to the lack of stable solid electrolyte interphase and dendrite growth, and existing cold sintering processes result in low ionic conductivity and integration challenges with organic materials.
Innovation Solution
A process involving the application of pressure and heat to a mixture of a lithium-based ceramic and a polar solvent with a dissolved lithium salt, allowing for the formation of lithium salt-ceramic composites at temperatures no greater than 250°C, which enhances ionic conductivity and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature sintering process (~1000°C) is used to produce dense electrolytes with high ionic conductivity, then ionic conductivity and density are improved, but processing cost increases, lithium loss occurs, impurity phase formation occurs, and integration with organic materials is precluded
Solution Approach 1:
The patent changes the processing temperature parameter from conventional high-temperature sintering (~1000°C) to low-temperature sintering (900-1000°C), which resolves the contradiction by achieving high ionic conductivity while reducing processing cost and enabling integration with organic materials. The temperature parameter is optimized to balance densification requirements with material stability and cost considerations.
Solution Approach 2:
The patent creates composite electrolyte materials combining inorganic ceramic components with organic binder materials. This composite approach enables integration of both ceramic ion conductivity and organic material flexibility, resolving the contradiction between achieving high ionic conductivity and enabling integration with organic materials for flexible electronics.
2Manufacturing precision
If high-temperature sintering process (~1000°C) is used, then dense structure and high ionic conductivity are achieved, but lithium loss and impurity phase formation occur
Solution Approach 1:
The patent optimizes the sintering temperature parameter to a lower range (900-1000°C) that is sufficient to achieve dense structure and high ionic conductivity while preventing excessive lithium loss and impurity phase formation. This parameter optimization resolves the contradiction between achieving manufacturing precision and minimizing substance loss.
3Temperature
If conventional sintering temperature (~800°C) is used for cold sintering process, then processing temperature is reduced compared to conventional sintering, but ionic conductivity is low (3×10−6 S/cm)
Solution Approach 1:
The patent optimizes multiple parameters including sintering temperature (900-1000°C), pressure, and time to achieve a balance between low processing temperature and high ionic conductivity. By carefully controlling these parameters, the patent resolves the contradiction by achieving processing temperatures significantly lower than conventional sintering while maintaining ionic conductivity comparable to or exceeding conventional methods.
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 process achieves high ionic conductivity exceeding 10−4 S/cm and relative densities greater than 85%, comparable to conventionally sintered materials, while reducing grain boundary resistance and enabling stable cycling in lithium symmetric cells.
Implementation Method 1
a polar solvent having a lithium salt dissolved therein. The mixture can be prepared by combining a lithium based ceramic, a lithium salt with a polar solvent, such that the lithium salt dissolves in the polar solvent.
Implementation Method 2
applying pressure and heat to a mixture to form a lithium salt-ceramic composite wherein the heat applied to the combination is no greater than about 250° C.
Data Source
AI summary
Highly dense lithium based ceramics can be prepared by a low temperature process including combining a lithium based ceramic with a polar solvent having a lithium based salt dissolved therein and applying pressure and heat to the combination to form a salt-ceramic composite. Advantageously, the lithium salt is one that dissolves in the polar solvent and the heat applied to the combination is no greater than about 250° C. Such composites can also have high ionic conductivity.