Sintered Chalcogenide Electrodes for Thick Solid-State Batteries
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Solution Overview
Problem
Lithium-ion batteries face limitations in energy density, size, weight, cost, and temperature operation range due to irreversible reactions with liquid electrolytes, which restrict their performance and lifespan, particularly in applications like electric vehicles where quick charging and high energy demands are critical.
Innovation Solution
A sintered electrode with a chalcogenide compound, such as lithium cobaltite, is developed, featuring a thickness of 2 μm to 100 μm and a cross-sectional area of at least 3 cm², with porosity between 0.1% to 30%, allowing for rapid sintering and integration into batteries without additional finishing techniques, enhancing charge capacity and reducing inactive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional liquid electrolyte batteries are used, then battery technology is widely adopted, but energy density and volumetric capacity are limited
Solution Approach 1:
The patent changes the physical and chemical parameters of the electrolyte by transitioning from liquid to solid state, and modifies electrode parameters by using sintered ceramics with controlled porosity (0.1% to 30%). This enables higher energy density while maintaining compact volume through the specific pore size range of 0.01 μm to 1 μm that optimizes ion transport.
Solution Approach 2:
The invention uses composite structures combining sintered ceramic electrodes with solid electrolytes, creating a multi-phase material system that achieves both high energy density and efficient ion conduction. The composite nature allows optimization of each component's properties to overcome the limitations of conventional liquid electrolyte systems.
2Ease of operation
If liquid electrolyte is used, then battery operation is simple, but temperature operation range is restricted and overheating damage occurs
Solution Approach 1:
The patent replaces the liquid electrolyte system with a solid electrolyte system, fundamentally changing the physical state from liquid to solid. This substitution eliminates the temperature-related issues of liquid electrolytes while maintaining ease of operation through the self-supporting nature of the sintered electrode structure that requires no additional mechanical supports.
Solution Approach 2:
The sintered electrode structure is designed to be inherently stable and self-supporting, eliminating the need for additional protective components that would be required in liquid electrolyte systems to prevent overheating damage. The solid state nature provides intrinsic thermal stability.
3Ease of manufacture
If conventional electrodes are used, then manufacturing is straightforward, but additional finishing techniques like grinding or polishing are required
Solution Approach 1:
The sintered electrode structure is designed to be self-supporting with inherent mechanical strength from the sintering process. The controlled porosity and grain structure provide sufficient structural integrity without requiring additional mechanical supports or finishing operations, making the electrode self-sufficient and eliminating post-processing steps.
Solution Approach 2:
The invention extracts and eliminates the need for additional finishing techniques by incorporating the structural support function directly into the sintered electrode body. The sintering process itself creates the necessary mechanical strength, removing the need for separate grinding, polishing, or support substrate steps.
4Volume of stationary object
If thick electrodes are used to increase capacity, then volumetric capacity improves, but ion transport distance increases and performance decreases
Solution Approach 1:
The patent employs porous sintered ceramic electrodes with controlled porosity (0.1% to 30%) and specific pore sizes (0.01 μm to 1 μm). This porous structure provides interconnected pathways for ion transport throughout the electrode thickness, maintaining fast ion transport kinetics even in thick electrodes with high volumetric capacity.
Solution Approach 2:
The invention introduces a three-dimensional porous network structure within the electrode that provides multiple parallel ion transport pathways. This dimensional complexity allows ions to traverse thick electrodes efficiently by navigating through the porous network rather than traveling through dense material, effectively reducing the transport distance.
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 sintered electrode achieves a seven-fold higher volumetric capacity and ten-fold higher weight-based capacity compared to conventional batteries, supporting faster charging and extended cycle life while eliminating the need for mechanical supports, thus improving battery performance and efficiency.
Implementation Method 1
the green tape is sintered at a temperature of from 500° C. to 1350° C. for a time of no more than 60 min to form a sintered tape
Data Source
AI summary
A method for forming a sintered composition includes providing a slurry precursor including a chalcogenide compound; tape casting the slurry precursor to form a green tape; and sintering the green tape at a temperature in a range of 500° C. to 1350° C. for a time in a range of less than 60 min. An energy device includes a first sintered, non-polished electrode having a first surface and a second surface; a first current collector disposed on the first surface of the first electrode; an electrolyte layer disposed on the second surface of the first electrode; and a second electrode disposed on the electrolyte layer.