Perforated Solid-State Cathode With Glass-Ceramic Electrolyte Paths
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Solution Overview
Problem
Solid-state batteries face limitations in achieving high-rate capability and effective lithium ion transport due to random distribution of electrolyte particles, leading to high impedance and limited charge/discharge rates, especially with thick cathodes.
Innovation Solution
A solid-state battery cell design featuring a sintered metal oxide cathode with an array of cavities and a continuous glass or glass ceramic electrolyte separator that extends into these cavities, providing a high surface area interface and reducing tortuous conduction paths, along with a lithium-based anode in contact with the electrolyte on the opposite side.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If a thick cathode is used to increase energy density, then volumetric energy density is improved, but lithium ion transport becomes limited due to tortuous conduction paths and high impedance
Solution Approach 1:
The cathode is segmented into multiple layers separated by electrolyte-filled cavities, creating a multi-level structure that reduces tortuous conduction paths. The cavities divide the thick cathode into thinner effective segments, allowing lithium ions to travel shorter distances through the electrolyte and improving transport efficiency while maintaining high volumetric energy density.
Solution Approach 2:
The invention introduces a vertical dimension to lithium ion transport by creating cavities that extend into the cathode depth. Instead of relying solely on lateral transport through tortuous paths, lithium ions can move vertically through the electrolyte-filled cavities, creating a more direct conduction path and reducing the effective transport distance in thick cathodes.
2Ease of manufacture
If electrolyte particles are randomly distributed in the cathode, then manufacturing is simplified, but impedance increases and charge/discharge rates are limited
Solution Approach 1:
The invention replaces mechanical mixing and random distribution of electrolyte particles with a controlled chemical deposition process. The electrolyte is deposited from a slurry solution that penetrates the cathode structure, allowing uniform distribution through capillary action and chemical adhesion rather than mechanical mixing, thereby achieving both ease of manufacture and low impedance.
Solution Approach 2:
The cathode is designed with a porous structure containing cavities that facilitate electrolyte penetration and distribution. The porous architecture allows the electrolyte slurry to uniformly infiltrate the cathode matrix through capillary forces, ensuring consistent electrolyte distribution without requiring complex mechanical mixing processes, thus maintaining ease of manufacture while achieving high charge/discharge rates.
3Productivity
If a continuous electrolyte separator is used to reduce impedance, then lithium ion transport is enhanced, but manufacturing complexity increases
Solution Approach 1:
The invention merges the separator function with the cathode structure by integrating electrolyte-filled cavities directly into the cathode matrix. Rather than using a separate continuous separator layer, the electrolyte is incorporated within the cathode's porous network, combining the electrode and separator functions into a single integrated structure, thereby reducing device complexity while maintaining enhanced lithium ion transport efficiency.
Solution Approach 2:
The use of porous cathode material with embedded cavities allows the electrolyte to form continuous conduction paths within the cathode structure itself. The porous architecture naturally creates interconnected channels for electrolyte flow, achieving continuous electrolyte connectivity without requiring complex external separator structures, thus enhancing lithium ion transport while keeping manufacturing relatively simple.
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
This design enhances lithium ion transport, reduces impedance, and enables higher discharge rates and energy density by ensuring continuous electrolyte connectivity and alignment with the voltage field gradient, addressing the limitations of previous solid-state battery configurations.
Implementation Method 1
a glass or glass ceramic electrolyte separator forming a smooth layer on the cathode surface and extending into the depths of the cavities of the cathode
Implementation Method 2
a non-homogeneous mixture of cathode active material and glass or glass ceramic electrolyte material, wherein a continuous electrolyte separator extends into cavities of a patterned cathode, providing high surface area interface
Implementation Method 3
a sintered metal oxide cathode, wherein a surface of the cathode has an array of cavities extending about 60-90% into a depth of the cathode
Implementation Method 4
ensuring continuous electrolyte connectivity and alignment with the voltage field gradient, addressing the limitations of previous solid-state battery configurations
Data Source
AI summary
A solid-state battery cell is provided, which contains a sintered metal oxide cathode, in which a surface of the cathode has an array of cavities extending about 60-90% into a depth of the cathode; a glass or glass ceramic electrolyte separator forming a smooth layer on the cathode surface and extending into the depths of the cavities of the cathode; and a lithium-based anode in contact with the electrolyte on a side opposite the cathode. A method of making the solid-state battery cell is also described.