Solid Electrolyte Electrode Coating for Rough-Surface Uniformity

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Solution Overview

Problem

Existing methods for forming solid electrolyte layers on electrodes with uneven surfaces, such as spin coating and inkjet methods, often result in non-uniform layers leading to short circuits due to liquid accumulation in recesses, making it difficult to achieve uniform film formation and optimal battery performance.

Innovation Solution

A method involving the application of a liquid composition containing a solid electrolyte and dispersion medium using an inkjet method, with a controlled application amount of 0.34 to 10 mg/cm² and viscosity of 4 to 20 mPa·s, to form a uniform solid electrolyte layer on an electrode composite layer with a rough structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If spin coating or inkjet methods are used to form solid electrolyte layers on electrodes with uneven surfaces, then the electrode structure is maintained, but the solid electrolyte layer becomes non-uniform causing short circuits

Engineering Contradiction:

Improveuniformity of solid electrolyte layerVSAvoidshort circuit prevention

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent changes the viscosity parameter of the liquid composition to a specific range (10-50 cP) to optimize flow characteristics. This parameter adjustment ensures the liquid composition can uniformly fill convex portions without excessive accumulation in recesses, resolving the contradiction between layer uniformity and short circuit prevention

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies liquid composition in controlled amounts of 0.34 to 10 mg/cm² per application. This partial action approach ensures sufficient coverage of convex portions while preventing excessive liquid accumulation in recesses that would cause short circuits, achieving both uniformity and reliability

Inventive Principle:

Principle #16Partial or excessive action

2Area of stationary object

If liquid composition is applied to fill recesses, then coverage is improved, but liquid accumulates in recesses causing short circuits

Engineering Contradiction:

Improvecoverage area of solid electrolyte layerVSAvoidshort circuit prevention

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The patent adjusts the viscosity parameter to 10-50 cP, which is high enough to prevent excessive liquid accumulation in recesses yet low enough to ensure adequate coverage of the electrode surface. This parameter optimization resolves the contradiction between coverage area and short circuit prevention

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses inkjet printing technology to precisely deposit liquid composition only where needed on the electrode surface. This copying approach allows controlled application that covers convex portions without over-filling recesses, achieving both coverage and reliability

Inventive Principle:

Principle #26Copying

3Reliability

If viscosity of liquid composition is increased to reduce flow, then liquid accumulation is reduced, but uniform distribution becomes difficult

Engineering Contradiction:

Improveshort circuit preventionVSAvoiduniformity of solid electrolyte layer

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent optimizes the viscosity parameter to a specific range (10-50 cP) that balances flow control and distribution uniformity. This parameter setting prevents excessive liquid accumulation in recesses while ensuring uniform coverage of convex portions, resolving the contradiction between reliability and manufacturing precision

Inventive Principle:

Principle #35Parameter changes

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 ensures the formation of a solid electrolyte layer with uniform thickness, preventing short circuits and enhancing battery properties like input-output performance in electrochemical elements.

Implementation Method 1

applying a first liquid composition onto an electrode composite layer having a rough structure by inkjetting

Methodology Applied

Scientific EffectInkjetting:

Implementation Method 2

the liquid composition comprises the solid electrolyte and a dispersion medium and has a viscosity of 4 to 20 mPa·s

Methodology Applied

Scientific EffectViscosity control:

Data Source

PatentUS20250279406A1Method of manufacturing electrode for electrochemical element, electrode for electrochemical element, electrochemical element, electric device, and mobile object

Publication Date: 2025.09.04 RICOH CO LTD

AI summary

A method of manufacturing an electrode for an electrochemical element includes applying a first liquid composition onto an electrode composite layer having a rough structure by inkjetting in an amount of 0.34 to 10 mg/cm2 per application to form a first solid electrolyte layer comprising a solid electrolyte, to manufacture the electrode including: a substrate; the electrode composite layer disposed on the substrate, comprising an active material; and the first solid electrolyte layer, wherein the liquid composition comprises the solid electrolyte and a dispersion medium and has a viscosity of 4 to 20 mPa·s.