All-Solid-State Battery Electrode Slurry Sequencing for Uniform Contact

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Solution Overview

Problem

The existing manufacturing methods for all-solid-state batteries result in non-uniform contact between the electrode active material and solid electrolyte, leading to reduced efficiency and energy density due to isolated solid electrolyte and electrode active material, which block lithium ion pathways.

Innovation Solution

A method involving the use of two different types of binders and solvents in sequential steps to prepare a primary and secondary slurry, where the conductive agent is added in the secondary slurry, ensuring uniform mixing and formation of triple points between the electrode active material, solid electrolyte, and conductive agent.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a compression molding method is used to manufacture the all-solid-state battery electrode, then the manufacturing process can be simplified, but the contact uniformity between electrode active material and solid electrolyte deteriorates

Engineering Contradiction:
Improvemanufacturing process simplicityVSAvoidcontact uniformity between electrode active material and solid electrolyte
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-mixing the electrode active material and solid electrolyte in a specific ratio before the compression molding process. This pre-mixing ensures that the components are uniformly distributed in advance, so that when compression molding is applied, the contact uniformity is maintained without requiring complex manufacturing processes. The slurry preparation step before molding is the key preliminary action that resolves the contradiction.

Inventive Principle:
Principle #10Preliminary action

2Device complexity

If electrode active material, solid electrolyte, conductive agent and binder are simultaneously mixed, then the manufacturing process is simplified, but the solid electrolyte pathways are blocked and energy density decreases

Engineering Contradiction:
Improvemixing process complexityVSAvoidenergy density
Core Design Contradiction:
Device complexityVSQuantity of substance

Solution Approach 1:

The patent applies segmentation by dividing the mixing process into distinct stages: first mixing the electrode active material and solid electrolyte to establish continuous pathways, then separately adding the conductive agent and binder in subsequent steps. This segmentation prevents the conductive agent and binder from blocking the solid electrolyte pathways during mixing, thereby maintaining high energy density while keeping the manufacturing process manageable through clear sequential steps.

Inventive Principle:
Principle #1Segmentation

3Ease of manufacture

If the contact surface between electrode active material and solid electrolyte is non-uniform, then the manufacturing process is simpler, but the electrochemical reaction efficiency and energy density are reduced

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidelectrochemical reaction efficiency
Core Design Contradiction:
Ease of manufactureVSProductivity

Solution Approach 1:

The patent applies parameter changes by optimizing the mixing ratio of electrode active material to solid electrolyte and controlling the particle size distribution of these components. By adjusting these parameters, the slurry achieves uniform flow and packing characteristics that result in uniform contact surfaces after compression molding. This resolves the contradiction by achieving both manufacturing simplicity and high electrochemical reaction efficiency through parameter optimization rather than complex processes.

Inventive Principle:
Principle #35Parameter changes

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 enhances the energy density of the all-solid-state battery by minimizing unnecessary solid electrolyte and expanding lithium ion pathways, resulting in improved performance.

Implementation Method 1

mixing an electrode active material, a solid electrolyte and a binder with a solvent to prepare a slurry

Methodology Applied
Scientific EffectHomogeneous mixing:

Implementation Method 2

drying the slurry to prepare an electrode

Methodology Applied
Scientific EffectEvaporation: Evaporation

Data Source

PatentUS12525614B2Method of manufacturing electrode of all-solid-state battery and electrode of all-solid-state battery manufactured using the same
Publication Date: 2026.01.13 LG ENERGY SOLUTION LTD
  • US12525614B2 patent drawing
  • US12525614B2 patent drawing
  • US12525614B2 patent drawing

AI summary

The present invention relates to a method of manufacturing an electrode of an all-in-one battery comprising the steps of mixing an electrode active material, a solid electrolyte and a first binder with a first solvent to prepare a primary slurry; drying the primary slurry to prepare a mixture powder; mixing the mixture powder, a conductive agent, and a second binder with a second solvent to prepare a secondary slurry; and coating the secondary slurry on a current collector.