Multi-Phase Electrolyte Film for Conductive, Lithium-Stable Cells
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Solution Overview
Problem
Current lithium-ion batteries face limitations in achieving high energy density due to low lithium conductivity in solid-state electrolytes, particularly when using lithium metal anodes, and existing ceramic electrolytes require high-temperature processing steps that are not commercially viable.
Innovation Solution
A multi-phase electrolyte film comprising a metal oxide and a lithium salt with a decomposition temperature above 200°C, dispersed in a 5-200 nanometer range, is deposited using a one-step spray pyrolysis process at reduced temperatures, providing improved lithium-ion conductivity and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high ionic conductivity solid-state electrolytes are used, then lithium conductivity is improved, but stability in the presence of lithium metal deteriorates
Solution Approach 1:
The patent employs a composite solid-state electrolyte comprising multiple materials (e.g., sulfide-based electrolyte combined with oxide coatings or interfacial layers) to simultaneously achieve high lithium conductivity and stability against lithium metal. The composite structure allows the bulk material to provide ionic conductivity while the interface layers prevent detrimental reactions with lithium metal anodes.
Solution Approach 2:
The patent applies local quality by creating distinct regions within the electrolyte structure: a bulk region optimized for high ionic conductivity and an interfacial region (through coatings or surface modifications) optimized for chemical stability with lithium metal. This spatial differentiation of material properties resolves the contradiction between conductivity and stability.
2Reliability
If ceramic electrolytes are used to improve stability, then reliability is improved, but processing temperature requirements increase
Solution Approach 1:
The patent utilizes parameter changes by controlling deposition conditions (temperature, pressure, composition ratios) during the formation of the solid-state electrolyte layer. By optimizing these parameters, the electrolyte achieves desired stability properties without requiring extreme processing temperatures, thus resolving the contradiction between stability and processing temperature.
Solution Approach 2:
The patent introduces intermediary materials or intermediate processing steps (such as buffer layers, precursor coatings, or controlled atmosphere treatments) that enable the formation of stable ceramic electrolyte structures at reduced temperatures. These intermediaries facilitate low-temperature synthesis while maintaining the stability characteristics of ceramic materials.
3Quantity of substance
If lithium metal anode is used to improve energy density, then energy density is improved, but safety deteriorates
Solution Approach 1:
The patent applies beforehand cushioning by incorporating protective interfacial layers or coating structures between the lithium metal anode and the electrolyte before assembly. These pre-formed protective layers prevent dendrite propagation and short circuits that could otherwise occur with lithium metal, thus maintaining safety while enabling high energy density.
Solution Approach 2:
The patent uses composite electrode structures where lithium metal is combined with protective matrix materials or surface coatings. This composite approach allows the lithium metal to provide high capacity while the surrounding composite structure prevents safety issues such as dendrite formation and thermal runaway.
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 multi-phase electrolyte film achieves high room temperature conductivity of 10−4 S/cm without additional heat treatment, competing favorably with alternative materials like LIPON and garnet-type ceramic electrolytes, while reducing processing temperatures and enhancing stability against lithium metal.
Implementation Method 1
spraying the mixture onto a solid substrate at a temperature of 150 to 500° C. to provide the multi-phase electrolyte film
Data Source
AI summary
A multi-phase electrolyte film includes a first phase comprising a metal oxide, wherein the metal oxide is amorphous, crystalline, or a glass; and a second phase comprising a lithium salt having a decomposition temperature in air of greater than 200° C. or a lithium halide. The first phase is dispersed in the second phase and has an average particle size of 5 to 200 nanometers. Methods for the manufacture of the electrolyte film are also disclosed.