Solid-State Electrolyte Composite for Battery Adhesion
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Solution Overview
Problem
Solid-state electrolytes face challenges in large-scale commercialization due to poor adhesion to electrodes and mechanical properties, leading to high bulk resistance and dendrite formation, with existing solutions compromising ionic conductivity when improving mechanical properties.
Innovation Solution
A solid-state electrolyte composition incorporating ionically conductive inorganic particles in a non-ionically conductive polymer matrix with a cross-linked polymer network, which maintains high ionic conductivity while allowing for dense, thin film formation and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic solid-state electrolytes are used, then ionic conductivity is improved, but adhesion to electrodes deteriorates
Solution Approach 1:
The patent employs a composite material system combining inorganic solid-state electrolyte particles (such as sulfide glasses or ceramics with high ionic conductivity) dispersed in a polymer matrix. This composite structure allows the inorganic phase to provide high ionic conductivity while the polymer phase provides mechanical compliance and adhesion to electrodes, thus resolving the contradiction between conductivity and adhesion.
2Reliability
If glass and ceramic solid-state conductors are used, then ionic conductivity is improved, but mechanical compliance deteriorates
Solution Approach 1:
The brittle inorganic solid-state conductors (glass or ceramic particles) are embedded in a ductile polymer matrix, creating a composite that inherits the high ionic conductivity of the inorganic phase while gaining the mechanical compliance and processability of the polymer phase, enabling fabrication into dense thin films.
Solution Approach 2:
The composite structure allows different regions to have different properties: the inorganic particles provide localized high ionic conductivity pathways, while the polymer matrix provides localized mechanical compliance and ductility. This spatial differentiation of properties resolves the contradiction between conductivity and manufacturability.
3Reliability
If film thickness is reduced, then bulk resistance is improved, but mechanical integrity deteriorates
Solution Approach 1:
The polymer-inorganic composite structure enables the formation of mechanically intact thin films because the ductile polymer matrix can accommodate the reduced thickness while maintaining structural integrity, preventing the film from becoming too brittle or prone to cracking that would occur with pure inorganic materials at thin dimensions.
4Strength
If polymer binder is added, then adhesion is improved, but ionic conductivity deteriorates
Solution Approach 1:
The invention uses a composite where the polymer phase serves as the binder matrix holding inorganic particles together, providing adhesion to electrodes. By optimizing the composition to have high inorganic particle content (at least 50 wt%, preferably 70-95 wt%), the ionic conductivity is maintained at high levels (≥1×10^-4 S/cm) despite the presence of polymer binder, as the inorganic phase provides the dominant ionic conduction pathways.
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 solution achieves high ionic conductivity and mechanical compliance, enabling efficient processing and adhesion to electrodes, preventing dendrite formation and facilitating the use of lithium metal anodes and sulfur cathodes.
Implementation Method 1
the non-ionically conductive polymer matrix includes a cross-linked polymer network
Implementation Method 2
ionically conductive inorganic particles... wherein the composition has an ion conductivity of at least 1×10−4 S·cm−1
Data Source
AI summary
Provided herein are methods of forming solid-state ionically conductive composite materials that include particles of an inorganic phase in a matrix of an organic phase. The methods involve forming the composite materials from a precursor that is polymerized in-situ after being mixed with the particles. The polymerization occurs under applied pressure that causes particle-to-particle contact. In some embodiments, once polymerized, the applied pressure may be removed with the particles immobilized by the polymer matrix. In some implementations, the organic phase includes a cross-linked polymer network. Also provided are solid-state ionically conductive composite materials and batteries and other devices that incorporate them. In some embodiments, solid-state electrolytes including the ionically conductive solid-state composites are provided. In some embodiments, electrodes including the ionically conductive solid-state composites are provided.