Melt-Infiltrated Solid-State Electrolyte With Interphase Layer

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Solution Overview

Problem

Conventional solid-state lithium-ion batteries face limitations such as low ionic conductivity, low energy density, high costs, and safety concerns due to brittle ceramic electrolytes, which restrict their application in high-energy devices like electric vehicles and consumer electronics.

Innovation Solution

The development of a solid-state Li-ion battery cell using an inorganic, melt-infiltrated solid electrolyte with an interphase layer comprising metals like Zr, Al, or their oxides, and a cathode active material with high nickel content, combined with conductive carbon and porous anode particles to enhance energy density and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solid electrolytes are used to enhance safety, then fire resistance is improved, but energy density decreases

Engineering Contradiction:

Improvefire resistanceVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies local quality by creating an interphase layer with specific metal compositions (Zr, Al, K, Cs, Fr, Be, Mg, Ca, Sr, Ba, Sc, Y, La, or non-La lanthanoids, Ta, Zr, Hf, and Nb) at the electrode-electrolyte interface. This localized modification allows the solid electrolyte to maintain its fire-resistant properties while the interphase layer enhances ionic conductivity and energy density at the critical interface region.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining the solid electrolyte with an interphase layer comprising multiple metals and their oxides. This composite structure at the interface enables the system to simultaneously achieve the fire resistance of solid electrolytes and the high ionic conductivity needed for high energy density, resolving the contradiction between safety and performance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If solid electrolytes are used to enhance safety, then fire resistance is improved, but power density decreases

Engineering Contradiction:

Improvefire resistanceVSAvoidpower density

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The interphase layer with specific metal compositions is applied locally at the electrode-electrolyte interface to enhance ionic conductivity where it is most needed for power delivery, while the bulk solid electrolyte maintains its fire-resistant properties.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The composite interphase layer structure combines multiple metals and oxides to achieve high ionic conductivity at the interface, enabling high power density while the overall solid-state system maintains fire resistance.

Inventive Principle:

Principle #40Composite materials

3Reliability

If interphase layer is added to reduce interfacial resistance, then manufacturing complexity increases, but cycle stability improves

Engineering Contradiction:

Improvecycle stabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The interphase layer is formed as a preliminary step during battery manufacturing, depositing the metal layer onto the electrode or electrolyte surface before final assembly. This preliminary action ensures proper interface formation and reduces interfacial resistance from the outset, improving cycle stability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The interphase layer acts as an intermediary between the electrode and solid electrolyte, mediating the interface properties to reduce resistance and improve stability. This intermediary layer simplifies the overall system by providing a stable, low-resistance interface that enables reliable operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 results in higher energy density, improved cycle stability, and reduced interfacial resistance, facilitating safer and more efficient battery operation across a wider temperature range, while also simplifying manufacturing and reducing costs.

Implementation Method 1

at least a portion of at least one of the electrode surfaces comprises an interphase layer separating the respective electrode active material from direct contact with the SSE

Methodology Applied

Scientific EffectInterfacial separation:

Implementation Method 2

an inorganic, melt-infiltrated, solid state electrolyte (SSE) ionically coupling the anode electrode and the cathode electrode

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 3

inorganic, melt-infiltrated, solid state electrolyte

Methodology Applied

Scientific EffectMelt infiltration:

Data Source

PatentUS11837697B2Battery cell including an inorganic, melt-infiltrated, solid-state electrolyte

Publication Date: 2023.12.05 GEORGIA TECH RES CORP

AI summary

In an aspect, a solid-state Li-ion battery (SSLB) cell, may comprise an anode electrode comprising an anode electrode surface and an anode active material, a cathode electrode comprising a cathode electrode surface and an cathode active material, and an inorganic, melt-infiltrated, solid state electrolyte (SSE) ionically coupling the anode electrode and the cathode electrode, wherein at least a portion of at least one of the electrode surfaces comprises an interphase layer separating the respective electrode active material from direct contact with the SSE, and wherein the interphase layer comprises two or more metals from the list of: Zr, Al, K, Cs, Fr, Be, Mg, Ca, Sr, Ba, Sc, Y, La or non-La lanthanoids, Ta, Zr, Hf, and Nb.