Battery Separator Rapid Sintering for Porosity and Ion Conductivity
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Solution Overview
Problem
Existing methods for fabricating solid-state lithium metal battery separators are inefficient and do not produce materials with desirable characteristics for conducting lithium ions effectively.
Innovation Solution
Rapid thermal processing (RTP) methods involving high temperatures and short durations are employed to sinter materials like LATP, LAGP, or LLZO, with heating elements positioned close to the material being sintered, using silicon carbide, molybdenum, or carbon heating elements, to produce separators with controlled proximity and temperature ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional sintering methods are used to fabricate solid-state electrolyte separators, then the separators can be produced, but the fabrication efficiency is low and the separators do not achieve desirable lithium ion conductivity
Solution Approach 1:
The patent applies rapid thermal processing by dramatically changing the temperature-time parameters of the sintering process. Instead of conventional slow sintering, the method uses temperatures of 900-2000°C for only 5 seconds to 30 minutes. This parameter change enables both high fabrication efficiency and desirable lithium ion conductivity in the separators
2Productivity
If heating elements are positioned close to the material for rapid heating, then thermal processing efficiency improves, but the risk of contact between heating elements and material increases
Solution Approach 1:
The patent introduces an intermediary atmosphere (inert or reducing gas) between the heating elements and the material being processed. This intermediary layer enables the heating elements to be positioned very close to the material for efficient heat transfer while preventing direct contact that could cause contamination or damage
3Productivity
If high temperatures are used for short periods to improve fabrication efficiency, then productivity increases, but precise control of temperature and time is required
Solution Approach 1:
The patent implements feedback control systems that continuously monitor and adjust the temperature and time parameters during rapid thermal processing. This feedback mechanism enables precise control of the high-temperature short-duration process, ensuring consistent separator quality while maintaining high fabrication efficiency
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 RTP methods efficiently produce separators with optimal porosity and conductivity for lithium ions, enhancing the performance of solid-state lithium metal batteries.
Implementation Method 1
rapid thermal processing (RTP) to fabricate separators in solid-state lithium metal batteries... sintering material at high temperatures for short periods of time... heating elements may be from about 1 millimeter to about 2000 millimeters from the material being sintered
Implementation Method 2
heating elements may comprise different forms of silicon carbide, molybdenum or carbon... heating elements in sufficient proximity to the material being sintered
Implementation Method 3
sintering material at high temperatures for short periods of time to produce the separators... sintered material may comprise LATP, LAGP, or LLZO
Data Source
AI summary
Methods and apparatus for fabricating separators for solid-state lithium metal batteries employ rapid thermal processing. Aspects include high temperature sintering. Temperatures, durations of heat application, and proximity of heating elements to materials undergoing sintering combine to provide separators with desirable physical characteristics, including porosity, in a batch process.