LTP Solid Electrolyte Production With Fine-Grain Field-Assisted Sintering
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Solution Overview
Problem
Conventional methods for producing lithium titanium phosphate (LTP) solid electrolytes are inefficient, requiring costly and time-consuming steps like drying, milling, and pre-sintering, and often result in materials with large grain sizes that are prone to mechanical failure.
Innovation Solution
A process involving flame pyrolysis to produce a particulate precursor material followed by field-assisted sintering, which eliminates the need for drying and milling, and produces materials with small grain sizes and enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sintering methods are used to produce LTP solid electrolytes, then the material can be formed, but the grain sizes become large which leads to poor mechanical reliability and susceptibility to mechanical failure
Solution Approach 1:
The patent applies field-assisted sintering which fundamentally changes the sintering parameters by applying high electric fields (10-100 V/cm) during the sintering process. This enables sintering at lower temperatures (900-1100°C) with shorter holding times (5-30 minutes), effectively controlling grain growth and producing fine-grained microstructures with improved mechanical reliability
Solution Approach 2:
The patent employs periodic pulsed electric fields during sintering, where the electric field is applied in pulses rather than continuously. This periodic action promotes uniform grain growth and prevents excessive grain coarsening, maintaining fine grain sizes while achieving complete densification
2Ease of manufacture
If conventional production methods including drying and milling steps are used, then the precursor material can be prepared, but the process becomes costly and time-consuming
Solution Approach 1:
The patent merges the drying and milling steps into a single calcination step performed directly on the gel precursor. The gel is calcined at 400-600°C to remove organic components and form the precursor powder in one operation, eliminating the need for separate drying and milling operations, thereby simplifying the process and reducing production time
Solution Approach 2:
The patent performs preliminary formation of a gel precursor with controlled composition and morphology before sintering. This gel precursor is directly convertible to the final product through calcination and field-assisted sintering, eliminating the need for intermediate processing steps and streamlining the overall manufacturing process
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 yields LTP solid electrolytes with exceptional mechanical properties and competitive lithium ion conductivity, making them suitable for industrial electrolysis and energy storage applications.
Implementation Method 1
subjecting the generated aerosol to flame pyrolysis to form a particulate precursor material therefrom
Implementation Method 2
subjecting the particulate precursor material to field-assisted sintering to form the lithium titanium phosphate based solid electrolyte material
Data Source
AI summary
A process for producing a lithium titanium phosphate based solid electrolyte material is disclosed, the process comprising the steps of: (i) providing a solution comprising a Li source material, a Ti source material, a P source material and optionally a Si source material and/or a source material of a metal M, wherein M is selected from the group of Al, Ga, Ge, In, Sc, V, Cr, Mn, Co, Fe, Y, the lanthanides or a combination thereof; (ii) generating an aerosol from the solution; (iii) subjecting the generated aerosol to flame pyrolysis to form a particulate precursor material therefrom; and (iv) subjecting the particulate precursor material to field-assisted sintering to form the lithium titanium phosphate based solid electrolyte material. Furthermore, disclosed are a solid electrolyte material obtainable through said production process and articles comprising the same.