Sulfide Solid Electrolyte Furnace Layout to Prevent Sulfur Adhesion

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Solution Overview

Problem

The existing methods for producing sulfide-based solid electrolytes in a gas atmosphere containing sulfur face challenges with sulfur adhesion to apparatus parts, leading to blockages and reduced productivity.

Innovation Solution

The method involves separating a sulfur-excess atmosphere portion from areas in the heating furnace where sulfur adhesion is likely to occur, using a partition within the furnace to create distinct spaces for the melt and the sulfur supply, thereby preventing sulfur adhesion to critical apparatus structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If heating and melting are performed in a gas atmosphere containing sulfur element, then composition control is improved and sulfur deficiency is prevented, but sulfur adhesion to apparatus parts occurs causing blockages

Engineering Contradiction:

Improvecomposition controlVSAvoidcontinuous production capability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The heating furnace is divided into multiple temperature zones along the heating direction, with the sulfur supply portion located in a high-temperature zone and the raw material charge portion and product discharge portion located in lower-temperature zones. This spatial segmentation prevents sulfur adhesion in critical areas while maintaining sulfur-excess atmosphere where needed for composition control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A temperature gradient is introduced as an intermediary mechanism between the sulfur supply and the raw material charge/discharge portions. The gradual temperature change acts as a buffer that prevents direct sulfur adhesion in low-temperature areas while maintaining the necessary sulfur atmosphere in high-temperature areas.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If sulfur is supplied in excess to prevent composition deficiency, then manufacturing precision is improved, but sulfur adhesion and blockages increase

Engineering Contradiction:

Improvesulfur composition controlVSAvoidsulfur adhesion

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

Different regions of the heating furnace are provided with different sulfur partial pressures and temperatures. The sulfur supply portion maintains high sulfur concentration and high temperature to prevent composition deficiency, while the charge and discharge portions operate at lower temperatures where sulfur adhesion is minimized, achieving local optimization of both composition control and adhesion prevention.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The temperature parameter is varied along the heating direction to control sulfur behavior. By maintaining high temperature in the sulfur supply zone and lower temperature in the charge/discharge zones, the patent changes the physical state and reactivity of sulfur locally, preventing adhesion while ensuring proper composition.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If the heating furnace operates with sulfur supply, then product quality is improved, but apparatus blockages occur reducing ease of operation

Engineering Contradiction:

Improveproduct qualityVSAvoidapparatus maintenance

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The heating furnace structure is segmented into distinct functional zones: a sulfur supply portion in the high-temperature region, and separate charge/discharge portions in lower-temperature regions. This segmentation isolates the sulfur supply function from the charge/discharge operations, preventing blockages in the latter while maintaining product quality through controlled sulfur supply.

Inventive Principle:

Principle #1Segmentation

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 by preventing sulfur adhesion and blockages within the apparatus, allowing for continuous and stable production of sulfide-based solid electrolytes.

Implementation Method 1

dividing a space between the melt and the heating furnace by the partition into a first space in which the sulfur supply portion is located and a second space in which the other structure is located

Methodology Applied

Scientific EffectPhysical separation by partition:

Implementation Method 2

forming a sulfur-excess atmosphere portion by introducing a component containing a sulfur element into the first space from the sulfur supply portion

Methodology Applied

Scientific EffectGas phase sulfur supply:

Implementation Method 3

heating and melting a raw material in a heating furnace

Methodology Applied

Scientific EffectThermal heating and melting: Melting

Data Source

PatentUS20250070238A1Method and apparatus for producing sulfide solid electrolyte

Publication Date: 2025.02.27 AGC INC

AI summary

A method for producing a sulfide-based solid electrolyte includes heating and melting a raw material in a heating furnace. The heating furnace includes a sulfur supply portion, a partition provided inside the heating furnace, and one or more other structures capable of allowing an inside and an outside of the heating furnace to communicate with each other. The method includes: forming a melt by heating and melting the raw material; dividing a space between the melt and the heating furnace by the partition into a first space in which the sulfur supply portion is located and a second space in which the other structure is located; and forming a sulfur-excess atmosphere portion by introducing a component containing a sulfur element into the first space from the sulfur supply portion.