Solution-Based Synthesis of Solid Sodium Ion-Conductive Electrolytes
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Solution Overview
Problem
Current methods for synthesizing NASICON ceramics are time-consuming and prone to material loss and contamination, limiting their large-scale manufacturing and reproducibility due to extended processing times and the need for ball-milling processes.
Innovation Solution
A solution-based method involving the formation of an alkaline or aqueous mixture with sodium salts, metal oxides, and phosphorous precursors, followed by neutralization, concentration, and sintering at temperatures between 900° C to 1250° C, which significantly reduces processing time and enhances the efficiency of NASICON ceramic fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ball-milling synthesis methods are used, then NASICON ceramics can be produced, but the processing time is extended to several days to a week
Solution Approach 1:
The patent replaces the conventional mechanical ball-milling process with a solution-based chemical synthesis method. Instead of mechanically grinding and mixing solid precursors for extended periods, the invention dissolves metal oxides and carbonates in acidic solutions to form precursor solutions, which are then dried and sintered to produce NASICON ceramics with high conductivity in significantly reduced time.
Solution Approach 2:
The invention changes the physical and chemical parameters of the synthesis process by transitioning from solid-state mechanical mixing to solution-phase chemical reactions. This involves changing the state of matter from solid to dissolved, adjusting pH levels through acid-base reactions, and controlling solution concentration to achieve optimal precursor formation for rapid sintering.
2Manufacturing precision
If extended ball-milling processes are used, then NASICON pellets can be fabricated, but material loss and contamination occur
Solution Approach 1:
The patent eliminates the mechanical ball-milling step that causes material loss through spillage, adhesion to mill walls, and cross-contamination between batches. The solution-based method uses controlled chemical reactions in contained vessels, significantly reducing material loss and contamination risks while maintaining product quality.
Solution Approach 2:
The invention introduces acidic solutions as intermediary carriers for the metal precursors. Instead of directly mixing solid powders, the metal oxides and carbonates are first dissolved in acids to form homogeneous precursor solutions, which then serve as intermediates that uniformly distribute all components before sintering, preventing segregation and contamination.
3Manufacturing precision
If conventional synthesis methods are used, then NASICON ceramics can be produced, but large-scale manufacturing is limited
Solution Approach 1:
The patent replaces the time-consuming mechanical ball-milling process with a solution-based method that scales more efficiently. The solution preparation and drying steps can be easily scaled up by simply increasing the volume of solutions used, and the process time remains relatively short even for large batches, enabling better large-scale manufacturing productivity.
4Manufacturing precision
If conventional synthesis procedures are used, then NASICON pellets can be fabricated, but the procedures are hard to replicate
Solution Approach 1:
The invention changes the synthesis approach to solution-based chemistry with clearly defined parameters such as solution concentration, pH level, drying temperature, and sintering conditions. These parameters are more easily controlled and standardized than mechanical ball-milling variables, leading to improved reproducibility and ease of replication across different laboratories and production facilities.
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 method allows for the rapid synthesis of dense, non-porous, solid sodium ion-conductive electrolytes in approximately 12 hours, making it suitable for large-scale manufacturing and improving the reproducibility and conductivity of NASICON ceramics, while also being applicable to non-NASICON materials.
Implementation Method 1
neutralizing the alkaline mixture with a solution comprising at least one phosphorous precursor
Implementation Method 2
sintering the solid at a temperature in the range of 900° C. to 1250° C.
Implementation Method 3
concentrating the neutralized mixture to form a paste; removing the liquid from the paste to form a solid
Data Source
AI summary
Disclosed is a rapid, reproducible solution-based method to synthesize solid sodium ion-conductive materials. The method includes: (a) forming an aqueous mixture of (i) at least one sodium salt, and (ii) at least one metal oxide; (b) adding at least one phosphorous precursor as a neutralizing agent into the mixture; (c) concentrating the mixture to form a paste; (d) calcining or removing liquid from the paste to form a solid; and (e) sintering the solid at a high temperature to form a dense, non-porous, sodium ion-conductive material. Solid sodium ion-conductive materials have electrochemical applications, including use as solid electrolytes for batteries.