All-Solid-State Battery Thin-Layer Manufacturing via Ion-Conducting Mediator
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Solution Overview
Problem
Current lithium ion battery manufacturing techniques face challenges such as electrolyte degradation, porosity issues, and interdiffusion at interfaces, leading to reduced performance and safety concerns, particularly in solid-state batteries.
Innovation Solution
A method for manufacturing all-solid thin film batteries using successive steps involving deposition of anode, cathode, and solid electrolyte layers, followed by heat treatment and mechanical compression, to achieve compact, high-performance layers without interdiffusion, using techniques like electrophoresis and recrystallization at controlled temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum deposition techniques are used to deposit solid electrolyte layers, then manufacturing precision and interface quality are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces an intermediary organic compound layer between the inorganic solid electrolyte and electrode materials. This organic layer serves as a mediator that simplifies the manufacturing process by enabling low-temperature deposition while maintaining good interface contact, thus reducing the need for complex vacuum deposition equipment and high-temperature processing while still achieving precise interface definition.
Solution Approach 2:
The patent changes the deposition temperature parameter from high temperature (required for vacuum deposition) to low temperature (below 150°C) by using solution-based deposition methods. This parameter change allows the use of simpler manufacturing equipment while maintaining acceptable interface quality through the intermediary organic layer.
2Strength
If high temperature sintering is used to consolidate electrode layers, then mechanical strength is improved, but interdiffusion at interfaces increases causing harmful chemical compounds
Solution Approach 1:
The patent uses an organic compound as an intermediary barrier layer between different electrode and electrolyte materials. This intermediary layer prevents direct interdiffusion and harmful chemical reactions that would occur during high-temperature sintering, while still allowing ionic conduction. The organic layer acts as a protective mediator that eliminates the harmful effects of high-temperature processing.
Solution Approach 2:
The patent changes the consolidation temperature from high temperature (sintering) to low temperature (below 150°C) deposition and drying processes. This parameter change prevents thermally-driven interdiffusion and unwanted chemical reactions while still achieving adequate mechanical consolidation through the deposition process and mild drying conditions.
3Reliability
If liquid electrolytes based on aprotic solvents are used, then ionic conductivity is improved, but operational safety and durability worsen due to degradation and thermal runaway
Solution Approach 1:
The patent creates a composite electrolyte system consisting of an inorganic solid electrolyte layer (for high ionic conductivity and thermal stability) combined with an organic compound intermediary layer (for flexibility and interface compatibility). This composite structure combines the advantages of both material types while eliminating their respective disadvantages - the solid inorganic electrolyte prevents thermal runaway while the organic layer ensures good interface contact and flexibility.
Solution Approach 2:
The patent changes the electrolyte physical state from liquid (aprotic solvent-based) to solid (inorganic compound-based). This parameter change fundamentally eliminates the degradation and thermal runaway issues associated with liquid electrolytes while maintaining high ionic conductivity through the solid inorganic material. The solid electrolyte operates at lower temperatures and does not undergo the violent degradation seen in liquid systems.
4Reliability
If electrode porosity is increased to ensure electrolyte wetting, then ionic transport is improved, but volume and mass energy densities decrease
Solution Approach 1:
The patent introduces an organic compound as an intermediary that facilitates ionic transport through a different mechanism than traditional electrolyte wetting. The organic intermediary layer provides continuous ionic conduction pathways that do not require high electrode porosity, allowing dense electrode structures to maintain good ionic transport efficiency. This eliminates the need to sacrifice energy density for ionic transport.
Solution Approach 2:
The patent changes the ionic transport mechanism from electrolyte-filled porosity to direct solid-state ionic conduction through the deposited layers. This parameter change allows electrodes to be deposited as dense, low-porosity structures while maintaining efficient ionic transport through the solution-deposited electrolyte and organic intermediary layers, thereby preserving high volume and mass energy densities.
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 batteries with enhanced power and energy density, improved mechanical rigidity, and increased lifespan, while avoiding the limitations of traditional methods like vacuum deposition and high-temperature sintering.
Implementation Method 1
depositing a layer of an organic compound on the inorganic solid electrolyte layer
Implementation Method 2
heat treatment and/or mechanical compression of the stack obtained in step e) is carried out to obtain an entirely solid thin-film battery
Implementation Method 3
the said layer of the said solution of the ionically conductive material obtained in step d) is dried in order to obtain a layer of an ionically conductive material
Implementation Method 4
heat treatment and/or mechanical compression of the stack obtained in step e) is carried out to obtain an entirely solid thin-film battery
Data Source
AI summary
The invention relates to a method for manufacturing an all-solid-state battery made up of thin layers, including the following consecutive steps: a) depositing a layer including at least one anode material on the conductive substrate thereof; b) depositing a layer including at least one cathode material on the conductive substrate thereof; c) depositing a layer including at least one solid electrolyte material on at least one layer obtained in step a) and/or b); d) depositing a layer of an ion-conducting material with a thickness of less than 10 µm, preferably less than 5 µm, and more preferably less than 2 µm, either on the layer of anode material coated with a layer of solid electrolyte material and/or on the layer of cathode material optionally coated with a layer of solid electrolyte material, or on the layer of cathode material coated with a layer of solid electrolyte material and/or on the layer of anode material optionally coated with a layer of solid electrolyte material; e) drying said layer of said solution of the ion-conducting material obtained in step d) in order to obtain a layer of an ion-conducting material; f) consecutively stacking a layer of anode material obtained in step a), c) or e), face-to-face, with a layer of cathode material obtained in step b), c) or e), with the proviso that the stack includes at least one layer of solid electrolyte material obtained in step c) and at least one layer of an ion-conducting material obtained in step e); and g) thermally treating and/or mechanically compressing the stack obtained in step e) to obtain an all-solid-state battery made up of thin layers.