Multi-Phase Electrolyte Film for Low-Temperature Solid-State Batteries
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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-temperature processing steps are used to manufacture ceramic electrolytes, then lithium-ion conductivity is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent changes the temperature parameter from high-temperature (above 900°C) to low-temperature (below 400°C) processing. This is achieved by using a spray pyrolysis method that deposits precursor materials which then convert to the functional electrolyte phase at reduced temperatures, directly resolving the contradiction between achieving high conductivity and maintaining ease of manufacture
Solution Approach 2:
The patent replaces traditional mechanical sintering processes with a chemical deposition approach (spray pyrolysis). Instead of mechanically heating and pressing ceramic powders at high temperatures, the invention uses a solution-based spray method followed by low-temperature thermal decomposition, substituting a complex mechanical-thermal process with a simpler chemical-thermal process
2Quantity of substance
If lithium metal is used as negative electrode to improve energy density, then energy density is improved, but stability in air deteriorates
Solution Approach 1:
The patent introduces an intermediary protective layer between the lithium metal and the environment. This electrolyte film acts as a barrier that prevents direct contact between lithium metal and air/moisture, while still allowing lithium-ion transport. The intermediary layer thus preserves both the high energy density benefit of lithium metal and provides the necessary air stability
Solution Approach 2:
The patent uses composite material structure combining the lithium metal anode with a protective electrolyte layer. This composite approach allows the system to exhibit both the high capacity of lithium metal and the stability of the protective layer, resolving the contradiction between energy density and air stability
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 and reduced processing temperatures, competing favorably with alternative materials like LIPON and garnet ceramic electrolytes, while maintaining 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.