Solid-State Battery Layer Spraying for Low-Impedance Throughput
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Solution Overview
Problem
Conventional solvent-based processing methods for manufacturing solid-state batteries result in high impedance and lack of high-throughput, primarily due to the use of solvents and binders, as well as poor contact between battery elements.
Innovation Solution
A solvent-free and binder-free energy-assisted spray processing method is employed to fabricate solid-state batteries, using cold spray or thermal spray techniques to form dense layers without the need for solvents or binders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solvent-based processing methods with binding polymer are used, then the manufacturing process is conventional and easier to implement, but the resulting solid-state batteries suffer from high impedance and cannot achieve high-throughput production
Solution Approach 1:
The patent extracts and eliminates the harmful components (solvents and binding polymers) from the conventional processing method. By using solvent-free energy-assisted spraying, the method removes the source of high impedance and poor contact, achieving both high throughput production and low impedance batteries simultaneously
Solution Approach 2:
The patent changes the physical and chemical parameters of the processing method by transitioning from solvent-based to solvent-free energy-assisted spraying. This parameter change enables rapid deposition (high throughput) while creating dense, well-contacted layers (low impedance), resolving the technical contradiction
2Reliability
If solvent-based processing methods are used, then the manufacturing process follows conventional approaches, but the contact between battery elements is poor leading to high impedance
Solution Approach 1:
The patent replaces conventional mechanical processing methods with energy-assisted spraying. This substitution enables precise control of material deposition, creating dense layers with excellent ionic contact between battery elements while maintaining process simplicity
Solution Approach 2:
By changing the processing parameters to energy-assisted spraying conditions, the patent achieves superior ionic contact quality through controlled material deposition, while the method remains relatively simple and scalable
3Productivity
If binding polymer is used in processing, then the conventional method can be followed, but the solid-state batteries cannot achieve high-throughput production
Solution Approach 1:
The patent extracts and removes the binding polymer from the processing formulation, enabling solvent-free energy-assisted spraying. This elimination allows for rapid production (high throughput) while the method remains straightforward to implement, maintaining ease of manufacture
Solution Approach 2:
The patent changes the processing parameters to eliminate the need for binding polymers and solvents, using energy-assisted spraying instead. This parameter change enables high-throughput production while keeping the manufacturing process simple and scalable
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 significantly reduces impedance and enables high-throughput production of solid-state batteries by improving ionic contact between the electrolyte and electrodes, while eliminating the issues associated with solvent and binder use.
Implementation Method 1
The processing method may be a solvent-free energy-assisted spray process, wherein a kinetic energy is used to form a dense layer
Implementation Method 2
In another aspect, the energy-assisted spray process may be a thermal spray method
Data Source
AI summary
A solvent-free processing method for manufacturing a solid-state battery that includes a first solid-state electrolyte layer and a first cathode layer. The method includes forming at least one of the first solid-state electrolyte layer and the first cathode layer by solvent-free energy-assisted spraying.