Porous Solid Electrolyte Layer Thickness Control to Suppress Resistance
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Solution Overview
Problem
Existing solid electrolyte layers face issues with increased resistance due to the exposure of the support material on the surface, which is not adequately addressed in previous manufacturing methods.
Innovation Solution
A manufacturing method that controls the thickness of the solid electrolyte layer to be 1.1 to 3.3 times the thickness of the support, ensuring the electrolyte is sufficiently supported and minimizing exposure, thereby reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the solid electrolyte layer is made thin to improve energy density, then energy density is improved, but the layer becomes difficult to make self-supporting and may expose the support material
Solution Approach 1:
The patent employs a porous support structure that provides mechanical strength and self-supporting capability while allowing the solid electrolyte to be deposited within the pores. The porous structure enables the thin film to maintain integrity without excessive thickness, thus achieving both high energy density and reliability.
Solution Approach 2:
The patent creates a composite structure combining the support material with the solid electrolyte layer. The support provides mechanical strength while the solid electrolyte fills the pores and provides ionic conductivity. This composite approach allows the thin film to be self-supporting while maintaining high energy density.
2Object-affected harmful factors
If the solid electrolyte layer is made thin to reduce resistance, then resistance is reduced, but the support material may be exposed on the surface causing increased resistance
Solution Approach 1:
The patent optimizes the thickness ratio parameter between the solid electrolyte layer and the support, specifying that the solid electrolyte thickness should be 0.05 to 2 times the support thickness. This parameter control ensures the solid electrolyte adequately covers the support surface while maintaining thin overall thickness to reduce resistance.
Solution Approach 2:
The patent replaces traditional coating methods with infiltration or in-situ formation methods where the solid electrolyte is deposited within the porous support structure. This substitution ensures uniform distribution and adequate surface coverage without requiring precise mechanical thickness control, thus reducing resistance while maintaining manufacturing feasibility.
3Reliability
If a support is added to make the solid electrolyte layer self-supporting, then self-supporting capability is improved, but the overall thickness increases and may expose the support
Solution Approach 1:
The patent embeds the solid electrolyte within the porous structure of the support, creating a nested configuration where the electrolyte fills the internal pores of the support. This nesting allows the support to provide self-supporting capability while the electrolyte remains contained, minimizing overall thickness increase and preventing support exposure.
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 approach effectively suppresses the increase in resistance by maintaining the support's structural integrity and preventing cracks, resulting in a more reliable solid electrolyte layer and battery performance.
Implementation Method 1
drying the support coated with the slurry to remove the dispersion medium
Data Source
AI summary
The present disclosure provides a solid electrolyte layer, a manufacturing method thereof, and a solid-state battery capable of suppressing an increase in resistance. A method for manufacturing a solid electrolyte layer 30, comprising: providing a slurry containing a solid electrolyte 20, a binder, and a dispersion medium, coating the slurry onto a support 10 having pores 12, and drying the support 10 coated with the slurry to remove the dispersion medium, wherein, in the coating of the slurry, the coating is performed such that, after drying, the thickness of the solid electrolyte 20 is 1.1 times or more and 3.3 times or less the thickness of the support, the solid electrolyte layer 30 obtained by this method, and the solid-state battery containing the solid electrolyte layer 30.