All-Solid-State Battery Layer Deposition for Low Interfacial Resistance
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Solution Overview
Problem
Existing methods for manufacturing all-solid-state batteries face challenges such as long firing times, residual carbon generation, and interfacial resistance due to high resin content and solvent volatilization rates, which hinder productivity and battery performance.
Innovation Solution
The method involves using a particle generator to convert electrode and electrolyte slurries into fine particles, which are then impacted onto a collector or electrode layer to form a dense, high-adhesion laminated structure with reduced binder content, allowing for rapid solvent evaporation and improved interface contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high resin content is used in the slurry to ensure adequate binder function, then adhesion between layers is improved, but residual carbon generation increases during firing
Solution Approach 1:
The patent changes the chemical composition parameters of the binder from conventional organic resins to inorganic materials (alumina sol, silica sol, colloidal alumina, colloidal silica). This parameter change allows the binder to provide adequate adhesion without generating residual carbon during firing, as inorganic materials do not carbonize like organic resins.
Solution Approach 2:
The patent uses firing at 400°C or lower under nitrogen gas atmosphere to debinder the binder, creating an oxidizing environment that prevents carbon residue formation while maintaining binder removal efficiency. The controlled atmosphere ensures complete oxidation of any organic components without generating excessive residual carbon.
2Object-generated harmful factors
If long firing time is used to eliminate binder completely, then residual carbon is reduced, but productivity decreases
Solution Approach 1:
The patent changes the binder composition to inorganic materials that decompose at lower temperatures (400°C or lower) compared to conventional organic resins. This parameter change reduces the firing temperature and time required to eliminate the binder completely, thereby reducing residual carbon while maintaining or improving productivity.
Solution Approach 2:
The patent employs a binder system designed for complete decomposition and removal during firing. The inorganic binder materials are selected to decompose fully at relatively low temperatures, leaving no persistent residue and requiring minimal firing time, thus acting as a temporary binding agent that serves its purpose and then disappears.
3Strength
If high resin content is used in the slurry to ensure adequate binder function, then adhesion between layers is improved, but manufacturing time increases
Solution Approach 1:
The patent changes the binder from organic resin to inorganic materials that decompose at lower temperatures (400°C or lower). This parameter change reduces the firing time required to remove the binder, thereby reducing manufacturing time while maintaining adhesion performance through the inorganic binder's binding capabilities.
Solution Approach 2:
The patent enables the firing process to proceed more quickly by using a binder that decomposes rapidly at lower temperatures. The inorganic binder materials are selected for their fast decomposition kinetics, allowing the manufacturing process to 'rush through' the binder removal stage without prolonged heating, thus reducing overall manufacturing time.
4Loss of time
If rapid solvent volatilization is achieved to improve productivity, then manufacturing time is reduced, but interfacial resistance increases due to poor particle contact
Solution Approach 1:
The patent applies the slurry to the electrode layer and allows rapid solvent volatilization to occur immediately upon application. This preliminary action of rapid drying ensures that particles are deposited in a dense configuration from the start, creating good initial contact between layers before any subsequent processing, thus maintaining low interfacial resistance despite the speed of the process.
Solution Approach 2:
The patent uses a die head for slurry application, which utilizes pneumatic pressure to deliver the slurry uniformly onto the electrode layer. This pneumatic delivery system ensures proper slurry distribution and particle arrangement during rapid solvent volatilization, maintaining good interfacial contact and low resistance even during fast processing.
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 productivity, minimizes residual carbon, and reduces interfacial resistance, resulting in improved battery performance and faster manufacturing times.
Implementation Method 1
convert the slurry containing the particles and solvent, or the particles, solvent, and binder as a binding agent between the particles into particles by a spray or particle generator
Implementation Method 2
adhere the particles to the object in a dense and strong manner after evaporation of the solvent
Data Source
AI summary
To lower electrical resistance by increasing the interfacial surface area and the adhesion between a current collector and an active material or an electrolyte, or between the active material and the electrolyte in an all-solid-state battery. In addition, to improve battery performance by eliminating or minimizing residual carbon originating from a binder. A slurry, composed of an electrode active material and a solvent, and a slurry, composed of electrolyte particles and a solvent, can be impacted against a target and thereby attached thereto to form a high-density layer and improve adhesion. Moreover, residual carbon is eliminated or minimized by eliminating or minimizing the content of binders, thereby improving battery performance.