Solid-State Lithium-Ion Conductor Quenching for Stable Powder Conductivity
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Solution Overview
Problem
Current methods for producing solid-state lithium-ion conductors face challenges with high contact resistances and low conductivities due to the use of liquid electrolytes, and the integration of solid-state conductors with other battery components often results in leaching of ions, especially in phosphate-based materials like lithium aluminum titanium phosphate (LATP), making it difficult to achieve adequate conductivity and stability.
Innovation Solution
A method involving the use of water and/or steam as a medium during the heating and cooling processes, including quenching and comminution steps, to produce a solid-state lithium-ion conductor material with high conductivity, using processes such as melting, sintering, ceramization, and calcination, while maintaining material stability and phase purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid-state lithium-ion conductors are produced by mixing with other battery components and sintering, then integration with battery components is achieved, but high contact resistances and low conductivities occur
Solution Approach 1:
The patent applies preliminary action by pre-synthesizing the solid-state lithium-ion conductor material with controlled particle size and morphology before integration with battery components. This pre-preparation ensures optimal conductivity and contact properties when the material is later integrated into the battery structure, avoiding the need for high-temperature sintering that causes contact resistance.
Solution Approach 2:
The patent utilizes parameter changes by controlling the synthesis temperature, particle size distribution, and phase composition of the solid-state lithium-ion conductor. By optimizing these parameters during synthesis, the material achieves high conductivity without requiring subsequent high-temperature sintering processes that would increase contact resistance and reduce overall conductivity.
2Reliability
If phosphate-based solid-state lithium-ion conductor materials are produced using conventional methods, then material stability is achieved, but ion leaching occurs reducing functionality
Solution Approach 1:
The patent applies parameter changes by precisely controlling the stoichiometry, sintering temperature, and atmosphere during synthesis of phosphate-based solid-state lithium-ion conductors. These parameter optimizations create a stable crystal structure with reduced ion leaching, maintaining both material stability and functionality simultaneously.
Solution Approach 2:
The patent employs composite material strategies by combining phosphate-based compounds with other materials that stabilize the structure and prevent ion leaching. This composite approach maintains material stability while eliminating the harmful leaching effect that would otherwise reduce functionality.
3Productivity
If water or steam is used as forming medium in heating process, then production efficiency is improved, but material stability and phase purity are compromised
Solution Approach 1:
The patent uses an intermediary approach by introducing water or steam as a transient medium during specific stages of the heating process, but controlling its presence and removal timing. This allows efficient heat and mass transfer during synthesis while preventing water from interfering with the final phase purity and material stability through controlled evaporation and atmosphere management.
4Ease of manufacture
If solid-state conductors are integrated in powder form with other battery components, then manufacturing simplicity is achieved, but high contact resistances occur
Solution Approach 1:
The patent applies parameter changes by optimizing the particle size, surface area, and morphology of the solid-state lithium-ion conductor powder before integration. By controlling these parameters during synthesis, the material achieves better contact properties and lower contact resistance while maintaining the simplicity of powder-form integration with other battery components.
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 method produces a solid-state lithium-ion conductor material with a conductivity of at least 10−5 S/cm at room temperature and a water content of <1.0 wt%, overcoming the limitations of traditional methods by ensuring high conductivity and stability, suitable for large-scale industrial production.
Implementation Method 1
carrying out at least one heating process with the starting products of the solid-state lithium-ion conductor material to obtain an intermediate product
Implementation Method 2
cooling or quenching of the intermediate product; wherein, in step (3) and/or step (4), the intermediate product is brought into contact with water and/or steam
Implementation Method 3
the heating process is selected from the group consisting of a melting process, a sintering process, a ceramization process, a calcination of a sol-gel precursor
Implementation Method 4
the heating process is selected from the group consisting of a melting process, a sintering process, a ceramization process, a calcination of a sol-gel precursor
Data Source
AI summary
In a method for producing a solid-state lithium-ion conductor material, water and/or steam is used as a medium during the cooling or quenching of an obtained intermediate product. The intermediate product can be comminuted and/or subjected to a cooling process, resulting in the production of a powder in one or more comminution steps. The solid-state lithium-ion conductor material has an ion conductivity of at least 10−5 S/cm at room temperature and a water content of <1.0 wt %. The solid-state lithium-ion conductor material can be used in the form of a powder in batteries or rechargeable batteries, preferably lithium batteries or rechargeable lithium batteries, in particular, separators, cathodes, anodes, or solid-state electrolytes.