Electrode-Electrolyte Lamination for Solid-State Cell Interface Contact
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Solution Overview
Problem
Solid-state electrochemical cells face issues with reduced interfacial contact between the electrode and electrolyte layers, leading to shorting, premature degradation, reduced capacity, and increased resistance.
Innovation Solution
The method involves providing a laminate with an electrode and an electrolyte by reducing the surface roughness of the electrode and/or heating the electrolyte material to a temperature of 100°C to 300°C, which improves interfacial contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the electrode surface is left rough as manufactured, then manufacturing is simpler and faster, but interfacial contact between electrode and electrolyte is reduced
Solution Approach 1:
The electrode surface is prepared in advance by reducing roughness through polishing, etching, or plasma treatment before electrolyte deposition. This preliminary action ensures optimal interfacial contact is established before the electrolyte is applied, preventing contact issues that would develop later during cell operation.
Solution Approach 2:
The surface roughness parameter of the electrode is actively modified and controlled within specific ranges (e.g., RMS roughness of 0.1-10 micrometers) to optimize interfacial contact. By changing the surface morphology parameters through controlled processing, the invention achieves improved contact without fundamentally altering the manufacturing approach.
2Reliability
If the electrolyte is deposited at room temperature, then the deposition process is simpler, but mechanical stress in the electrolyte increases causing delamination
Solution Approach 1:
The deposition temperature parameter is increased to the range of 100-300°C to reduce mechanical stress in the electrolyte layer. This temperature parameter change allows the electrolyte to be deposited with reduced internal stress, preventing delamination and maintaining stable interfacial contact during cell operation.
Solution Approach 2:
Heating the electrolyte during deposition utilizes thermal effects to reduce mechanical stress. The elevated temperature allows the electrolyte material to relax internal stresses and conform better to the electrode surface, improving adhesion and preventing delamination that would occur at room temperature.
3Reliability
If the electrolyte is heated to reduce mechanical stress, then delamination is reduced, but energy consumption increases
Solution Approach 1:
The electrolyte is heated and stress-relieved during the initial deposition process rather than requiring separate post-processing heating steps. This preliminary action consolidates multiple functions (deposition, stress relief, and adhesion optimization) into a single process, reducing total energy consumption while maintaining reliable interfacial contact.
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 performance of the electrochemical cell by achieving at least 80%, 90%, or 95% contact area between the electrode and electrolyte, reducing mechanical stress in the electrolyte, and minimizing delamination.
Implementation Method 1
heating the electrolyte material to a temperature of from 100° C. to 300° C. reduces mechanical stress in the electrolyte
Implementation Method 2
the electrolyte material is heated to a temperature below its glass transition temperature. Without wishing to be bound by theory, it is believed that heating the electrolyte material to a temperature close to, but lower than, its glass transition temperature allows the electrolyte material to better conform to the surface of the electrode
Data Source
AI summary
Methods of providing laminates are disclosed. In examples, the method involves providing an electrode containing electrode material; providing an electrolyte on a surface of the electrode, the electrolyte containing electrolyte material; and at least one of: reducing the roughness of the surface of the electrode before providing the electrolyte on the surface of the electrode; or heating the electrolyte material to a temperature of from 100°° C. to 300° C. Also described herein are methods of reducing mechanical stress in electrolytes, methods of reducing roughness of surfaces of electrodes, methods of providing electrochemical cells, electrochemical cells, and electrically-powered devices.