Solid Electrolyte Particle Growth Using Molten Sulfur
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Solution Overview
Problem
Existing techniques are inadequate for increasing the particle size of sulfide-based solid electrolytes, which is crucial for maximizing physical contact between electrolyte particles and active materials in battery electrodes, thereby limiting the performance of solid-state batteries.
Innovation Solution
A process involving combining sulfide-based solid electrolytes with molten elemental sulfur at elevated temperatures, followed by separation, to increase particle size and decrease surface area, utilizing a closed or partially closed vessel to manage sulfur vapor pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If established techniques are used to reduce particle size of solid electrolyte material, then particle size is decreased, but the ability to increase particle size is lost
Solution Approach 1:
The patent applies parameter changes by utilizing temperature as a control parameter to achieve particle size increase. Specifically, heating the solid electrolyte material to elevated temperatures (e.g., above the melting point of sulfur) enables particle growth through controlled interaction with molten sulfur, thereby expanding the particle size adjustment range beyond what conventional reduction techniques can achieve.
Solution Approach 2:
The patent employs phase transitions of sulfur as a key mechanism for particle size control. By transitioning sulfur from solid to liquid phase at elevated temperatures and then allowing it to cool and solidify around the electrolyte particles, the process enables particle size increase. This phase transition approach provides a new dimension for particle size adjustment that complements conventional reduction methods.
2Strength
If particle size of solid electrolyte material is increased, then physical contact with electrode particles is maximized, but conventional techniques cannot achieve this
Solution Approach 1:
The patent introduces molten sulfur as an intermediary substance to facilitate particle size increase. The sulfur acts as a medium that surrounds and binds to the solid electrolyte particles during heating, enabling controlled particle growth. This intermediary approach provides a practical manufacturing method for increasing particle size to optimize physical contact with electrode materials.
Solution Approach 2:
The patent utilizes temperature parameter changes to enable particle size increase for maximizing physical contact. By controlling the temperature profile during processing (heating above sulfur's melting point, holding at elevated temperature, then cooling), the process achieves particle size enlargement that improves electrolyte-electrode contact, making the manufacturing process adaptable to performance requirements.
3Length of stationary object
If solid electrolyte is combined with molten elemental sulfur at elevated temperature, then particle size increases by greater than 10%, but process complexity increases
Solution Approach 1:
The patent leverages the phase transition properties of sulfur to simplify the overall process despite the added step of heating. By exploiting sulfur's well-defined melting and solidification points, the process achieves particle size increase through a relatively simple thermal cycle (heat, hold, cool), avoiding the need for complex equipment or multiple processing steps.
Solution Approach 2:
The patent applies self-service by utilizing sulfur's inherent properties (melting point, viscosity, solidification behavior) to drive the particle size increase process. The molten sulfur automatically surrounds and binds to electrolyte particles when heated, and the particles grow through this self-organizing process without requiring external intervention or complex control mechanisms.
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 process effectively increases the average particle size by 10% or more and decreases the surface area by 10% or more, resulting in improved physical contact and performance of solid-state batteries.
Implementation Method 1
combining the solid electrolyte with molten elemental sulfur at a temperature greater than 100° C. for a period of time greater than 1 minute
Implementation Method 2
combining the solid electrolyte with molten elemental sulfur
Implementation Method 3
separating the solid electrolyte from the molten elemental sulfur by way of filtering, centrifuging, evaporating or combination thereof
Implementation Method 4
combining the solid electrolyte with molten elemental sulfur at a temperature greater than 100° C.
Data Source
AI summary
Methods for increasing the particle size of solid electrolyte materials include combining the solid electrolyte material with molten elemental sulfur. By combining the solid electrolyte material with molten elemental sulfur, the particle size of the solid electrolyte material increases and the specific surface area of the solid electrolyte material decreases.