Solid-State Battery Interface Bonding With Tempo-Spatial Ultrasonics

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Solution Overview

Problem

Challenges in manufacturing solid-state batteries include significant contact loss and increased interface resistance at the electrolyte-anode/cathode interface, leading to reduced ion transport and metal dendrite growth, which affects battery performance.

Innovation Solution

A tempo-spatial manipulation of ultrasonics (TSMU) is applied to the anode-electrolyte interface, involving sequential lateral, vertical, and lateral ultrasonic phases at reduced pressures, enhancing the bonding between the electrolyte and anode/cathode while minimizing electrolyte cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional liquid electrolyte is used in lithium-ion batteries, then ion transport is facilitated, but energy density is limited and safety issues arise

Engineering Contradiction:

Improvebattery safetyVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the physical state parameter of the electrolyte from liquid to solid, transitioning from conventional liquid electrolyte to solid-state electrolyte. This parameter change enables higher energy density and improved safety by eliminating the flammability and leakage issues inherent in liquid electrolytes while maintaining ion transport capability through the solid matrix

Inventive Principle:

Principle #35Parameter changes

2Reliability

If solid-state battery is implemented, then energy density and safety are improved, but interface resistance increases and contact loss occurs

Engineering Contradiction:

Improvebattery safetyVSAvoidinterface resistance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies ultrasonic vibration to the solid-state battery interface during assembly. This mechanical vibration facilitates better contact between the electrode and solid electrolyte, reduces interfacial resistance, and prevents contact loss by ensuring intimate physical contact between components that would otherwise have poor interface adhesion

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent employs periodic ultrasonic treatment at specific stages of battery assembly. This periodic action applies controlled vibrations during critical interface formation periods, ensuring optimal contact without continuous vibration that could damage the solid electrolyte structure

Inventive Principle:

Principle #19Periodic action

3Object-affected harmful factors

If ultrasonic treatment is applied to reduce interface resistance, then bonding is enhanced, but electrolyte cracking may occur

Engineering Contradiction:

Improveinterface resistanceVSAvoidelectrolyte structural integrity

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent applies ultrasonic treatment with controlled parameters that provide just enough vibration to improve interface contact without excessive energy input. This partial action approach enhances bonding sufficiently to reduce interface resistance while staying below the threshold that would cause structural damage or cracking to the solid electrolyte

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent maintains continuous monitoring and control of ultrasonic treatment parameters throughout the process. This continuity ensures that the beneficial bonding effect is sustained while immediately detecting and preventing conditions that could lead to electrolyte cracking, maintaining structural integrity throughout the treatment

Inventive Principle:

Principle #20Continuity of useful action

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

TSMU reduces interfacial resistance by up to 95%, maintaining structural integrity and preventing electrolyte cracking, thereby improving ion migration and battery performance.

Implementation Method 1

A tempo-spatial manipulation of ultrasonics (TSMU) is applied to the anode-electrolyte interface, involving sequential lateral, vertical, and lateral ultrasonic phases

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

TSMU reduces interfacial resistance by up to 95%, maintaining structural integrity and preventing electrolyte cracking

Methodology Applied

Scientific EffectCavitation: Cavitation

Data Source

PatentUS20250266420A1Tempo-spatial manipulation of ultrasonics for a solid-state battery

Publication Date: 2025.08.21 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Aspects of the disclosure include a tempo-spatial manipulation of ultrasonics (TSMU) for solid-state battery manufacturing and solid-state batteries manufactured using the same. An exemplary vehicle includes an electric motor and a battery pack electrically coupled to the electric motor. The battery pack includes a solid-state battery cell that includes an anode having a major surface, a solid electrolyte in direct contact with the anode, and an interface between the anode and the solid electrolyte. The interface is subjected to TSMU including a first ultrasonics phase at an emission angle parallel to the major surface of the anode, a second ultrasonics phase at an emission angle orthogonal to the major surface of the anode, and a third ultrasonics phase at an emission angle parallel to the major surface of the anode, thereby reducing an air gap between the anode and the solid electrolyte at the interface.