Solid-State Cell Layer Gradients for Lower Interfacial Resistance

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Solution Overview

Problem

Existing battery fabrication methods typically produce individual components separately and then combine them, which is inefficient and costly. There is a need for improved methods to construct multiple solid-state components directly within a battery container.

Innovation Solution

The method involves depositing multiple layers of distinct particle pluralities within a battery container, where at least a portion of the particles in each layer are fused together. A gradient of particles can be formed between layers to reduce interfacial resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple battery components are constructed separately using different fabrication methods and then combined, then each component can be optimized individually, but the overall fabrication process becomes complex and costly

Engineering Contradiction:

Improvecomponent optimizationVSAvoidfabrication process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple battery components (electrode, separator, electrolyte) into a single integrated structure formed by depositing multiple layers in one fabrication process. This merging eliminates the need for separate construction and assembly of individual components, reducing fabrication complexity while maintaining component optimization through controlled layer deposition parameters

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multi-layer deposition system serves multiple functions simultaneously: it deposits electrode materials, separator materials, and electrolyte materials in a single process. This universal approach replaces multiple specialized fabrication methods with one versatile deposition system that can construct all battery components in sequence

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If multiple battery components are constructed separately and then combined, then each component can be independently manufactured, but the overall fabrication time and cost increase

Engineering Contradiction:

Improveindependent component manufacturingVSAvoidfabrication efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The fabrication process continues without interruption by depositing multiple layers sequentially in one continuous operation. The deposition system transitions from depositing electrode material to separator material to electrolyte material without stopping, eliminating the time-consuming steps of separate manufacturing and assembly operations

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

All battery components are prepared and positioned in their final configuration during a single fabrication process rather than being manufactured separately and assembled later. The multi-layer structure is built in advance with all components integrated, eliminating subsequent assembly steps

Inventive Principle:

Principle #10Preliminary action

3Reliability

If distinct layers of particles are deposited to form multiple battery components, then component functionality is improved, but interfacial resistance between layers increases

Engineering Contradiction:

Improvecomponent functionalityVSAvoidinterfacial resistance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies different material properties to different layers while maintaining local optimization at each interface. Each layer is deposited with specific characteristics suited to its function (electrode, separator, electrolyte), and the deposition parameters are locally adjusted to ensure good interfacial contact and minimize resistance between adjacent layers

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The battery structure is formed as a composite of multiple material layers (electrode material, separator material, electrolyte material) deposited in sequence. This composite approach allows each layer to contribute its specific functional properties while the integrated deposition process ensures compatible interfaces between dissimilar materials

Inventive Principle:

Principle #40Composite materials

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 allows for the direct fabrication of electrochemical cells or batteries with multiple solid-state components within a single container, enhancing efficiency and reducing fabrication costs while improving performance by minimizing interfacial resistance.

Implementation Method 1

at least a portion of the first plurality of particles and/or at least a portion of the second plurality of particles are fused

Methodology Applied

Scientific EffectFusion:

Data Source

PatentUS20250132395A1Solid-state electrochemical cell components and related systems and methods

Publication Date: 2025.04.24 SION POWER CORP

AI summary

An electrochemical cell comprises a first layer comprising a first plurality of particles, a second layer adjacent to the first layer comprising a second plurality of particles and an interface between the first layer and the second layer, wherein the interface comprises a gradient of the first plurality of particles and the second plurality of particles, and wherein the gradient lowers the interfacial resistance between the two layers.