Spherical Solid Electrolyte Composite for Higher Li-Ion Conductivity

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Solution Overview

Problem

Existing lithium-ion batteries face challenges with self-destruction under misuse or extreme loads, and current solid-state electrolytes have insufficient chemical and electrochemical stability, making them unsuitable for widespread use in lithium batteries.

Innovation Solution

A lithium-ion-conducting composite material comprising at least one polymer and lithium-ion-conducting particles with high sphericity (≥0.7) and specific particle size distribution, allowing for higher particle fill levels, which is simpler and more economical to produce.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If spherical particles with high sphericity (≥0.7) and specific size distribution are used, then particle fill level and lithium-ion conductivity are significantly improved, but manufacturing complexity increases due to specialized production processes required

Engineering Contradiction:

Improvelithium-ion conductivityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies spheroidality by using spherical particles with sphericity ≥0.7 as the solid electrolyte material. This spherical shape enables higher particle fill levels in the battery structure and improves lithium-ion conductivity compared to conventional non-spherical particles. The spherical geometry facilitates better packing density and reduced interfacial resistance between particles

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent changes the particle size distribution parameters to achieve optimal performance. Specifically, it uses a controlled size distribution where particles range from 1-50 μm with a specific distribution profile, and controls the volume fraction of particles at different sizes to maximize fill level while maintaining good conductivity and electrochemical performance

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If solid-state electrolytes are used to replace liquid electrolytes, then safety is improved by preventing self-destruction and fire, but chemical and electrochemical stability is insufficient making them unsuitable for widespread use

Engineering Contradiction:

Improvesafety (prevention of self-destruction and fire)VSAvoidchemical and electrochemical stability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The patent uses composite materials by combining spherical solid electrolyte particles (such as LLZO, LATP, or LAGP) with a polymer matrix or binder material. This composite structure maintains the safety advantages of solid-state electrolytes while the polymer component provides flexibility and improved interfacial contact, enhancing overall electrochemical stability and performance

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional non-spherical particles are used, then manufacturing is simpler, but particle fill level and lithium-ion conductivity are significantly lower

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidlithium-ion conductivity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent replaces conventional mechanical grinding processes with specialized production methods such as spray drying, aerosol processing, or controlled precipitation that directly produce spherical particles. This substitution maintains manufacturing feasibility while achieving the desired spherical morphology and size distribution for optimal performance

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 composite material achieves significantly higher lithium-ion conductivity and easier processing, reducing interfacial resistance and enabling safer, more efficient lithium-ion batteries with improved stability and performance.

Implementation Method 1

lithium-ion-conducting composite material comprising at least one polymer and lithium-ion-conducting particles

Methodology Applied

Scientific EffectIon conduction: Conduction (electrical)

Implementation Method 2

reducing interfacial resistance and enabling safer, more efficient lithium-ion batteries

Methodology Applied

Scientific EffectInterfacial resistance reduction:

Data Source

PatentUS12573660B2Lithium-ion-conducting composite material containing polymer and monodisperse and spherical lithium-ion conducting particles and process for producing the same

Publication Date: 2026.03.10 SCHOTT AG

AI summary

A lithium-ion-conducting composite material and process of producing are provided. The composite material includes at least one polymer and lithium-ion-conducting particles. The particles have a sphericity ψ of at least 0.7. The composite material includes at least 20 vol % of the particles for a polydispersity index PI of the particle size distribution of <0.7 or are present in at least 30 vol % of the composite material for the polydispersity index in a range from 0.7 to <1.2, or are present in at least 40 vol % of the composite material for the polydispersity index of >1.2.