Multilayer Solid-State Li-Ion Battery Lamination for Uniform Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The commercialization of solid-state electrolytes for lithium ion batteries is hindered by challenges such as achieving uniform contact between the separator and electrodes, leading to lower cell performance and issues like lithium plating and dendrite formation, particularly in multilayer cells, due to poor adhesion and non-uniform densification, and the brittleness of glass and ceramic conductors which results in high bulk resistance and voids.
Innovation Solution
The method involves forming preformed cell elements with double-sided electrodes and composite electrolyte separators, which are laminated and densified using a calender press to ensure consistent thickness and adhesion, and then stacked with current collectors to create a multilayer cell through heat pressing, minimizing voids and improving mechanical properties without sacrificing ionic conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass and ceramic solid-state conductors are used to achieve high ionic conductivity, then ionic conductivity is improved, but the materials are too brittle to be processed into dense, thin films on a large scale, resulting in high bulk electrolyte resistance and dendrite formation
Solution Approach 1:
The patent uses composite electrolyte separators that combine glass or ceramic particles with a polymer matrix. This composite structure allows the brittle inorganic particles to provide high ionic conductivity while the polymer matrix provides flexibility and processability, enabling the formation of dense, thin films without dendrite formation or high bulk resistance
Solution Approach 2:
The patent modifies the mechanical properties of the electrolyte separator by controlling the particle size, concentration, and distribution of glass/c ceramic particles within the polymer matrix. This parameter optimization enables processing into dense thin films while maintaining high ionic conductivity and preventing dendrite penetration
2Device complexity
If conventional cell assembly processes are used to form multilayer cells, then cell assembly is simplified, but uniform contact between separator and electrodes is not achieved, leading to lower cell performance and lithium plating
Solution Approach 1:
The patent performs preliminary lamination of the separator to electrodes before final cell assembly. This pre-bonding step ensures uniform contact is established early in the process, preventing defects like lithium plating while maintaining a relatively simple overall assembly procedure
Solution Approach 2:
The patent combines multiple steps (lamination, densification, and assembly) into an integrated process where the separator is laminated to electrodes and the stack is densified together. This merging ensures uniform contact throughout the multilayer structure while keeping the process efficient
3Adaptability or versatility
If separator materials with poor adhesion are used, then material selection is easier, but adhesion to electrodes during battery cell assembly and cycling is poor, leading to lower cell performance
Solution Approach 1:
The patent uses composite electrolyte separators with polymer matrices that provide inherent adhesion properties. The polymer binder in the composite structure creates strong bonding interfaces with electrodes while allowing flexibility in selecting inorganic particle materials for ionic conductivity, thus maintaining both versatility and strength
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 highly dense electrodes and separators with improved adhesion, reducing voids and preventing lithium plating and dendrite formation, leading to enhanced energy density, conductivity, and stability in multilayer solid-state lithium ion batteries.
Implementation Method 1
densifying the separator/first electrode/first current collector/first electrode/separator stack
Implementation Method 2
heat pressing the multilayer cell
Implementation Method 3
heat pressing the multilayer cell
Data Source
AI summary
Provided herein are multilayer solid-state lithium ion batteries and methods of fabrication. In some embodiments, units of preformed cell elements and a current collector (of either the anode or cathode) are stacked. The preformed cell element includes a double-sided electrode, with separator/electrode on both sides of the double-sided electrode. The double-sided electrode may be an anode or a cathode. During the stacking process, the preformed cell elements are laminated to a cathode current collector or an anode current collector, as appropriate.