Solid Electrolyte Coating via Voltage-Triggered Sol-Gel Gelation
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Solution Overview
Problem
Current methods for forming solid electrolytes in solid-state batteries are hindered by long gelation times, making them unsuitable for practical integration and increasing manufacturing costs, especially when trying to produce thin layers or scale up production.
Innovation Solution
A method involving a sol-gel precursor solution that forms a gel in the presence of a voltage, allowing for rapid transformation and controlled gelification, particularly catalyzed near the electrode surface, enabling fast formation of solid electrolytes compatible with roll-to-roll and sheet-to-sheet manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sol-gel process is used to form solid electrolytes, then the electrolyte can be impregnated into porous electrodes and formed into composite electrodes, but the gelation step takes several days to complete, making the process unsuitable for practical manufacturing
Solution Approach 1:
The patent changes the pH parameter of the sol-gel precursor solution to acidic conditions (pH 2-7), which dramatically accelerates the gelation process from days to minutes or seconds. This parameter change enables practical manufacturing while maintaining the ability to form composite electrodes through impregnation of porous structures.
Solution Approach 2:
The patent performs preliminary acidification of the sol-gel precursor solution before impregnation, so that the gelation process is already primed to occur rapidly upon contact with the electrode or during the impregnation process itself, rather than requiring extended curing time afterward.
2Ease of operation
If a low viscosity precursor liquid is used for impregnation, then the precursor can flow into porous electrodes easily, but the liquid flows away from the foils during sheet-to-sheet or roll-to-roll processing, causing material loss
Solution Approach 1:
The patent applies a preliminary acidification treatment to the precursor liquid, which induces rapid gelation upon contact with the substrate. This preliminary chemical modification prevents the liquid from flowing away during processing while maintaining its ability to penetrate porous structures before solidifying.
Solution Approach 2:
The patent exploits the phase transition from liquid to gel state by controlling the pH of the precursor solution. The rapid gelation transforms the liquid precursor into a gel structure that remains on the foil surface during processing, preventing material loss while still allowing impregnation of porous electrodes.
3Reliability
If long curing times are used for gelation, then complete solidification of the electrolyte is achieved, but the manufacturing costs increase due to extended processing time
Solution Approach 1:
The patent changes the pH parameter to acidic conditions, which accelerates the gelation kinetics so that complete solidification occurs within minutes or seconds rather than days. This parameter modification maintains reliable solidification while dramatically improving manufacturing throughput and reducing costs.
4Reliability
If conventional sol-gel methods are used, then solid electrolytes can be formed, but the process is not suitable for producing thin layers or scaling up to industrial production
Solution Approach 1:
The patent modifies the pH parameter of the sol-gel precursor to acidic conditions, enabling rapid gelation that is compatible with continuous industrial processes such as roll-to-roll manufacturing. This allows both thin layer production and industrial scaling while maintaining reliable solid electrolyte formation.
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 solid electrolytes with comparable ion mobility to conventional methods but with significantly reduced manufacturing time and costs, facilitating the integration of composite electrodes into solid-state batteries while optimizing material usage and production efficiency.
Implementation Method 1
A method involving a sol-gel precursor solution that forms a gel in the presence of a voltage, allowing for rapid transformation and controlled gelification
Implementation Method 2
generating the voltage across the solution via the first and the second electrodes, thereby transforming the sol-gel precursor solution into a gel
Data Source
AI summary
A method for forming a solid electrolyte coating on a substrate (1), the method comprising: a. providing a first and a second electrode (3), b. coating a sol-gel precursor solution (4) of the solid electrolyte coating on the substrate (1) and electrically contacting the sol-gel precursor solution (4) with the first and the second electrode, the sol-gel precursor solution (4) being capable of forming a gel in presence of a voltage, and c. generating the voltage across the sol-gel precursor solution (4) via the first and the second electrodes, thereby transforming the sol-gel precursor solution (4) into a gel.