Solid State Battery Green Tape Lamination
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Solution Overview
Problem
Current Li-ion batteries using liquid electrolytes pose safety hazards due to flammability and reactivity, leading to potential fires and capacity imbalances in series stacking, which are addressed with costly safety measures that reduce energy density.
Innovation Solution
The development of solid state Li-ion batteries fabricated using a 'green tape' lamination and sintering process, where electrodes and separators are made from a mixture of active materials, conductive additives, and polymer binders, with a solid electrolyte, allowing for scalable and cost-effective high-volume manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If liquid electrolyte is used in Li-ion batteries, then ionic conductivity and electrochemical performance are improved, but safety hazards increase due to flammability and reactivity
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid to solid, fundamentally altering the safety properties while maintaining ionic conductivity through careful selection of solid electrolyte materials and optimization of their composition and structure
Solution Approach 2:
The patent employs composite solid electrolyte materials combining multiple components to achieve both high ionic conductivity and enhanced safety, creating a material system that simultaneously addresses performance and safety requirements
2Reliability
If thick separators are used to prevent shorts in liquid electrolyte batteries, then safety is improved, but energy density decreases
Solution Approach 1:
The patent changes the electrolyte state to solid, which fundamentally alters the separator requirements and enables thinner separator designs that maintain safety while improving energy density
Solution Approach 2:
The patent extracts the electrolyte function from a separate liquid component and integrates it into the solid electrode structure itself, eliminating the need for thick separate separators
3Reliability
If advanced separator structures with ceramic nano-particles are used, then short prevention is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the electrolyte to solid state, which simplifies the separator structure requirements and enables easier manufacturing while maintaining short prevention capabilities
4Reliability
If safety elements and monitoring systems are added to liquid electrolyte batteries, then safety is improved, but energy density and cost decrease
Solution Approach 1:
The patent extracts the safety function from separate monitoring systems and safety elements and integrates it into the solid electrolyte material itself, which inherently provides safety without requiring additional components
Solution Approach 2:
The solid electrolyte material provides its own safety functions (flame resistance, dendrite prevention, thermal stability) without requiring external monitoring systems or safety additives, making the system self-protecting
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 solid state batteries provide increased safety and higher energy density by eliminating flammable liquids, reducing the risk of fires, and enabling series stacking without capacity imbalances, thus enhancing reliability and efficiency.
Implementation Method 1
laminating together the green sheet of positive electrode material and the green sheet of separator material to form a laminated green stack
Implementation Method 2
sintering the laminated green stack to form a sintered stack comprising a positive electrode and a separator
Data Source
AI summary
Embodiments of the invention generally relate to solid state battery structures, such as Li-ion batteries, methods of fabrication and tools for fabricating the batteries. One or more electrodes and the separator may each be cast using a green tape approach wherein a mixture of active material, conductive additive, polymer binder and/or solid electrolyte are molded or extruded in a roll to roll or segmented sheet/disk process to make green tape, green disks or green sheets. A method of fabricating a solid state battery may include: preparing and/or providing a green sheet of positive electrode material; preparing and/or providing a green sheet of separator material; laminating together the green sheet of positive electrode material and the green sheet of separator material to form a laminated green stack; and sintering the laminated green stack to form a sintered stack comprising a positive electrode and a separator.