Sintered Solid-State Cell Structure for Thicker Conductive Electrodes
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Solution Overview
Problem
Manufacturing solid-state secondary cells is complex and expensive due to the difficulty in stacking thin layers of active materials and the need for controlled atmospheres to handle reactive precursor materials.
Innovation Solution
A solid-state electrochemical cell design featuring sintered layers of cathode, electrolyte, and anode materials, with the option of incorporating electrolyte material within the cathode and anode layers to improve conductivity and allow for thicker layers without reducing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin layers of active materials are deposited sequentially and stacked, then the solid-state electrochemical cell can be manufactured, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple thin layers of active materials into a single sintered layer structure. Instead of depositing and stacking multiple thin cathode and anode layers separately, the invention forms a consolidated sintered layer that integrates these materials, thereby simplifying the manufacturing process while maintaining the required layer structure and functionality.
Solution Approach 2:
The patent applies sintering treatment to transform the physical and chemical properties of the deposited precursor materials. By changing parameters such as temperature, pressure, and atmosphere during sintering, the precursor layers are converted into dense, conductive sintered layers with improved interfacial contact, eliminating the need for complex stacking operations.
2Manufacturing precision
If thin layers of active materials are stacked to form the cell, then the cell structure is complete, but the process is difficult and time-consuming with many opportunities for error
Solution Approach 1:
The patent merges multiple sequential deposition and stacking operations into a single sintering process. By consolidating the manufacturing steps, the invention eliminates the time-consuming nature of layer-by-layer stacking and reduces opportunities for human error while maintaining precise layer structure through controlled sintering parameters.
3Ease of manufacture
If precursor materials are handled in normal atmosphere, then the manufacturing process is simpler, but the reactive precursor materials require vacuum, inert, or tightly humidity-controlled atmospheres
Solution Approach 1:
The patent utilizes an inert or controlled atmosphere during the sintering process to protect reactive precursor materials from degradation. By maintaining a controlled atmosphere environment throughout the deposition and sintering operations, the invention prevents unwanted reactions while simplifying the overall process compared to requiring separate handling procedures for air-sensitive materials.
4Quantity of substance
If cathodes and anodes of greater thickness are used, then the capacity is increased, but the conductivity may be reduced
Solution Approach 1:
The patent employs sintering treatment to fundamentally change the physical and chemical parameters of the electrode materials. This process reduces porosity, increases density, and improves interfacial contact between particles and layers, thereby maintaining high conductivity even in thicker electrode structures. The sintering process creates optimal grain structure and eliminates defects that would otherwise impede charge transport.
Solution Approach 2:
The invention creates a composite sintered layer structure that integrates multiple functional materials (cathode active material, anode active material, electrolyte, and conductive additives) into a unified structure. This composite approach ensures continuous conductive pathways throughout the thicker electrode while maintaining electrochemical functionality, resolving the trade-off between thickness and conductivity.
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 improved interfacial contact and increased thickness of the cathode and anode layers enhance conductivity and capacity, simplifying the manufacturing process and reducing the number of cells required for a battery stack.
Implementation Method 1
a sintered cathode layer arranged on the cathode current collector, a sintered electrolyte layer arranged on the sintered cathode layer, a sintered anode layer arranged on the sintered electrolyte layer
Data Source
AI summary
Solid-state electrochemical cells are disclosed. In examples, the cell comprises a cathode current collector, a sintered cathode layer arranged on the cathode current collector, a sintered electrolyte layer arranged on the sintered cathode layer, a sintered anode layer arranged on the sintered electrolyte layer, and an anode current collector arranged on the anode layer. Also described herein are methods of manufacturing said solid-state electrochemical cells, battery stacks comprising a plurality of said solid-state electrochemical cells, and electrically-powered devices comprising the solid-state electrochemical cell or battery stack.