Solid-State Cell Electrolyte Transfer for Better Interfacial Contact
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Solution Overview
Problem
Manufacturing solid-state secondary electrochemical cells is complex and expensive due to the time-consuming and equipment-intensive process of depositing thin layers of active materials, which can lead to reduced interfacial contact between electrode and electrolyte layers, causing issues like shorting and premature degradation.
Innovation Solution
A method involving the deposition of an electrolyte layer on a substrate, followed by the separation of the electrolyte layer from the substrate, allowing for the formation of a component with a high electrode density and improved interfacial contact between the electrolyte and further electrodes, thereby enabling the creation of thinner, more efficient solid-state electrochemical cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin layers of active materials are deposited sequentially on top of each other, then the cell structure is formed, but the process becomes time-consuming and requires specialised equipment and conditions
Solution Approach 1:
The electrolyte layer is deposited on a substrate in advance, allowing subsequent electrode layers to be deposited directly on the electrolyte surface without requiring the substrate to be present during final cell assembly. This preliminary formation of the electrolyte layer simplifies the overall manufacturing process and reduces the need for specialised deposition equipment during final assembly.
2Manufacturing precision
If thin layers of active materials are deposited sequentially, then the cell structure is formed, but the process becomes complex and expensive
Solution Approach 1:
The manufacturing process is segmented into distinct stages: electrolyte layer deposition on substrate, electrode layer deposition on electrolyte, and final separation. This segmentation allows each stage to be optimized independently and simplifies the overall process by breaking down the complex sequential deposition into manageable steps.
Solution Approach 2:
The substrate serves as an intermediary during the manufacturing process, providing a temporary support for electrolyte layer deposition. After the electrolyte layer is formed and electrode layers are deposited, the substrate is removed, leaving the active components ready for assembly. This intermediary approach simplifies the manufacturing process by enabling easier handling and processing.
3Ease of manufacture
If electrode and electrolyte layers are deposited directly together, then assembly is simplified, but interfacial contact is reduced causing shorting and premature degradation
Solution Approach 1:
The electrolyte layer is preliminarily deposited on a substrate with controlled surface properties, ensuring optimal interfacial contact is established before electrode layers are added. This preliminary formation allows precise control of the electrolyte-substrate interface, preventing shorting and degradation while maintaining assembly simplicity.
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 results in solid-state electrochemical cells with improved interfacial contact, reduced ionic resistance, enhanced ionic conductance, and increased efficiency, while also allowing for the reuse of substrates and reducing material loss during the separation process.
Implementation Method 1
irradiating the substrate with electromagnetic radiation, thereby heating and expanding the first layer of the substrate, thereby separating the electrolyte layer and the substrate
Implementation Method 2
irradiating the substrate with electromagnetic radiation, thereby abating the first layer of the substrate, thereby separating the electrolyte layer and the substrate
Data Source
AI summary
Methods of making components for solid-state electrochemical cells are disclosed. In examples, the component comprises an electrode layer and an electrolyte layer, and the method: providing a substrate; depositing an electrolyte material on a first surface of the substrate to form an electrolyte layer on the substrate, wherein a first surface of the electrolyte layer contacts the first surface of the substrate along an interface; depositing an electrode material on a second surface of the electrolyte layer to form an electrode layer on the electrolyte layer, the second surface of the electrolyte layer being opposed to the first surface of the electrolyte layer; and separating the electrolyte layer from the substrate along the interface. Also described herein are methods of methods of providing solid-state electrochemical cells, solid-state electrochemical cells, battery stacks, and electrically-powered devices.