Plastic Crystal Electrolyte Interlayers for Flexible Solid-State Batteries
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Solution Overview
Problem
Existing solid-state electrolyte batteries face challenges with mechanical fragility, interfacial issues with electrodes, and high production costs due to the brittleness of inorganic powders and the difficulty in scaling up production processes like chemical and thermal vapor deposition.
Innovation Solution
A solid-state electrolyte battery design incorporating a solid-state electrolyte membrane with first and second plastic crystal electrolyte interlayers positioned between the anode and cathode, respectively, made from a mixture of polyethylene oxide, lithium lanthanum zirconium oxide, and lithium trifluoromethane sulfonimide, with the plastic crystal electrolytes enhancing mechanical resilience and ionic conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If rigid garnet or glass electrolytes are used to achieve high ionic conductivity, then ionic conductivity is improved, but mechanical flexibility and interfacial compatibility with electrodes deteriorate
Solution Approach 1:
The patent employs a composite electrolyte structure combining rigid inorganic solid electrolyte particles (providing high ionic conductivity) with a flexible polymer binder matrix (providing mechanical flexibility). This composite approach allows the electrolyte to simultaneously achieve high ionic conductivity through the inorganic phase while maintaining mechanical resilience and flexibility through the polymer phase, directly resolving the contradiction between ionic conductivity and mechanical flexibility
Solution Approach 2:
The patent creates a flexible thin-film solid electrolyte by forming a composite structure where inorganic electrolyte particles are embedded in a flexible polymer matrix. This enables the electrolyte to be processed into thin, flexible membranes that can conform to electrode surfaces, improving both mechanical handling properties and interfacial contact while maintaining high ionic conductivity through the inorganic phase
2Ease of manufacture
If thin films of solid electrolytes are made to improve mechanical flexibility and reduce interfacial resistance, then ease of manufacture and scalability are improved, but maintaining high ionic conductivity becomes more difficult
Solution Approach 1:
The composite structure with inorganic electrolyte particles dispersed in a polymer binder enables the fabrication of thin-film electrolytes using conventional coating techniques. The inorganic particles provide the ionic conduction pathways while the polymer matrix provides mechanical integrity, allowing thin films to be manufactured at scale without sacrificing ionic conductivity
Solution Approach 2:
The patent optimizes parameters including the size distribution of inorganic particles, the composition and molecular weight of the polymer binder, and the volume fraction of inorganic phase to maximize ionic conductivity in thin-film configurations. By controlling these parameters, the electrolyte maintains high ionic conductivity even at reduced thickness, enabling scalable manufacturing
3Manufacturing precision
If conventional vapor deposition or sputtering processes are used to make thin-film solid electrolytes, then film quality is improved, but production cost and manufacturing complexity increase
Solution Approach 1:
The patent replaces complex vacuum-based deposition processes (chemical vapor deposition, radio frequency sputtering, pulsed laser deposition) with simple solution-based coating methods. The composite electrolyte is applied as a slurry or solution that can be coated using conventional techniques such as dip-coating, spray-coating, or doctor-blade methods, then dried to form the thin film. This substitution dramatically reduces equipment requirements and manufacturing complexity while producing high-quality films
Solution Approach 2:
The patent changes the processing state of the electrolyte from requiring vapor-phase deposition to allowing solution-phase application. By formulating the electrolyte as a processable slurry or solution with appropriate viscosity and solids content, the material can be applied using simple coating techniques that are already well-established in the battery industry, eliminating the need for expensive vacuum deposition equipment
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 battery achieves reduced interfacial resistance, improved mechanical flexibility, and cost-effectiveness, enabling scalable and efficient production while maintaining high ionic conductivity, thus overcoming the limitations of traditional solid-state electrolytes.
Implementation Method 1
a first plastic crystal electrolyte interlayer, at least a portion of the first plastic crystal electrolyte interlayer being positioned between the solid-state electrolyte membrane and one of the anode and the cathode
Data Source
AI summary
Solid-state electrolyte battery and method for making same. In one embodiment, the solid-state electrolyte battery may include an anode, a cathode, and a solid-state electrolyte membrane, wherein the solid-state electrolyte membrane may be positioned between the anode and the cathode. The solid-state electrolyte membrane may be in the form of a layer having opposing surfaces. The solid-state electrolyte battery may further include a first plastic crystal electrolyte layer and a second plastic crystal electrolyte layer, wherein the first and second plastic crystal electrolyte layers may be similar to one another in structure and composition. At least a portion of the first plastic crystal electrolyte layer may be positioned between the anode and the first opposing surface of the solid-state electrolyte membrane. At least a portion of the second plastic crystal electrolyte layer may be positioned between the cathode and the second opposing surface of the solid-state electrolyte membrane.