Solid Electrolyte Layer Formation via Solution Coating
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Solution Overview
Problem
Existing methods for forming solid electrolyte layers in all-solid-state alkali metal secondary batteries face challenges such as low adhesion between electrode materials, high costs, and difficulty in continuous manufacturing, particularly with vapor-phase deposition techniques like pulse laser deposition.
Innovation Solution
A forming solution using a nonpolar organic solvent and a polar organic solvent with a higher polarity value is employed to create a solid electrolyte layer, allowing for continuous and cost-effective formation of the layer through a simple application method, with components like Li2S and MxSy, where M is selected from P, Si, Ge, B, Al, and Ga, enhancing adhesion and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pulse laser deposition technique is used to coat solid electrolyte on positive electrode active material, then adhesion between positive electrode active material and solid electrolyte becomes high and electric conductivity is enhanced, but the apparatus scale becomes large, manufacturing cost increases, and continuous manufacturing becomes difficult
Solution Approach 1:
The patent replaces the mechanical/physical vapor-phase deposition system (pulse laser deposition apparatus) with a chemical solution-based application system. The solid electrolyte is delivered as a solution containing dissolved or dispersed components that can be applied by simple coating methods, then converted to solid electrolyte layer through drying and heat treatment. This substitution dramatically simplifies the apparatus while achieving comparable or superior adhesion and conductivity.
Solution Approach 2:
The patent changes the physical state of the solid electrolyte from solid powder (vapor-phase deposition) to dissolved/dispered state (solution application). By controlling solution concentration, solvent type, and application parameters, the patent achieves uniform coating with good adhesion. The solution parameters (concentration, viscosity, solvent composition) are optimized to enable simple application while ensuring high-quality solid electrolyte layer formation after drying.
2Reliability
If a pulse laser deposition technique is used to coat solid electrolyte on positive electrode active material, then adhesion between positive electrode active material and solid electrolyte becomes high and electric conductivity is enhanced, but manufacturing cost becomes high and continuous manufacturing becomes difficult
Solution Approach 1:
The patent replaces the complex vapor-phase deposition system with a solution-based application system that enables continuous manufacturing. The solution can be applied continuously to electrode substrates using simple coating techniques (dip-coating, spray-coating, brush-coating), followed by continuous drying and heat treatment processes. This maintains high electric conductivity while enabling scalable production.
Solution Approach 2:
The patent enables continuous manufacturing by using a solution-based approach where the solid electrolyte solution can be continuously applied to electrode materials. The solution application, drying, and heat treatment processes can be performed in a continuous manner, allowing for high-volume production while maintaining consistent quality and high electric conductivity throughout the manufactured batteries.
3Ease of manufacture
If starting materials are pressed to form solid electrolyte layer, positive electrode and negative electrode integrated, then manufacturing is simple, but adhesion between source materials is low and sufficient electric conductivity cannot be obtained
Solution Approach 1:
The patent changes the physical state of the solid electrolyte from solid powder (pressing method) to dissolved/dispered state (solution application). The solution contains solid electrolyte components dissolved or dispersed in a solvent, allowing for uniform distribution and intimate contact with electrode active materials. After application and drying, this forms a coherent solid electrolyte layer with strong adhesion and high electric conductivity, while maintaining manufacturing simplicity.
4Ease of manufacture
If starting materials are pressed to form solid electrolyte layer, positive electrode and negative electrode integrated, then manufacturing is simple, but sufficient electric conductivity cannot be obtained
Solution Approach 1:
The patent changes the physical state of the solid electrolyte from solid powder (pressing method) to dissolved/dispered state (solution application). The solution contains solid electrolyte components dissolved or dispersed in a solvent, allowing for uniform distribution and intimate contact with electrode active materials. After application and drying, this forms a coherent solid electrolyte layer with strong adhesion and high electric conductivity, while maintaining manufacturing simplicity.
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 solution enables the formation of solid electrolyte layers with improved adhesion and conductivity, facilitating the production of all-solid-state alkali metal secondary batteries with enhanced electric conductivity and reduced manufacturing costs.
Implementation Method 1
a forming solution using a nonpolar organic solvent and a polar organic solvent with a higher polarity value is employed to create a solid electrolyte layer
Data Source
AI summary
A forming solution for forming a layer containing a solid electrolyte for an all-solid-state alkali metal secondary battery comprising a component derived from A2S and MxSy (A is selected from Li and Na; M is selected from P, Si, Ge, B, Al and Ga; and x and y are a number that gives a stoichiometric ratio in accordance with a species of M) as a starting material for manufacturing the solid electrolyte, a nonpolar organic solvent and a polar organic solvent having a polarity value higher than that of the nonpolar organic solvent by 0.3 or more.