Metal Sulfide Conversion Cathode Composite for Higher Solid-State Capacity

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Solution Overview

Problem

High nickel content cathode materials in solid-state batteries are expensive and challenging to utilize fully, limiting the cost-effectiveness of high-capacity battery packs.

Innovation Solution

Incorporating a molybdenum sulfide material in the cathode composite, with specific ratios and combinations of transition metal sulfides, conductive additives, solid electrolytes, and binders, to enhance the capacity and efficiency of solid-state electrochemical cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If high nickel content cathode materials (NMC) are used to increase energy storage capacity, then the energy density is improved, but the cost of the battery pack increases significantly

Engineering Contradiction:

Improveenergy storage capacityVSAvoidcost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent replaces expensive high-nickel NMC cathode materials with much cheaper sulfur-containing cathode materials (such as Li2SiO3-S composite materials). This substitution dramatically reduces the cost of cathode active material from thousands of dollars per kilogram to significantly lower costs, making high-capacity battery packs economically viable even if the sulfur-based materials have shorter operational lifespan or require different management strategies.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent employs composite cathode materials combining Li2SiO3 (lithium silicate) with sulfur-containing compounds. This composite approach allows the material to leverage the low cost and high theoretical capacity of sulfur while using Li2SiO3 to provide structural stability and improve electrochemical performance, thereby achieving both cost reduction and maintained functionality.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If sulfur containing cathode materials are used to reduce cost, then the cost is improved, but the capacity utilization becomes challenging

Engineering Contradiction:

ImprovecostVSAvoidcapacity utilization

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent introduces Li2SiO3 (lithium silicate) as an intermediary material that mediates between the sulfur-containing cathode material and the electrolyte/other cell components. This intermediary layer facilitates better ionic and electronic contact, improves the electrochemical accessibility of sulfur, and enables more complete capacity utilization of the sulfur-based cathode material, thereby resolving the capacity utilization challenge.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent optimizes various parameters including the composition ratios of Li2SiO3 to sulfur-containing materials, particle size distribution, sintering temperature and duration, and coating thicknesses. By carefully controlling these parameters, the patent achieves maximum capacity utilization of the sulfur-based cathode material, transforming it from a difficult-to-utilize material into a high-performance, cost-effective cathode option.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20260005242A1Metal sulfide containing conversion cathode design, and solid-state electrochemical cell containing thereof

Publication Date: 2026.01.01 SOLID POWER OPERATING INC

AI summary

Cathode composites include a transition metal sulfide and a molybdenum sulfide material. The composites display more favorable characteristics, such as charge capacity, as compared to known cathode composites.