Thin Free-Standing Electrolyte Layers for Solid-State Battery Power
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Solution Overview
Problem
Solid-state batteries face limitations due to thick solid-state electrolytes that reduce energy density and power capability, being suitable only for low currents and high temperatures.
Innovation Solution
Development of free-standing, thin electrolyte layers comprising a porous scaffold with a solution-processable solid-state electrolyte, such as sulfide-based particles, that fills the pores of the scaffold, enhancing conductivity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid-state electrolyte layers are made thicker to improve mechanical stability, then structural integrity is improved, but lithium ion conduction path increases which decreases energy density and power capability
Solution Approach 1:
The patent employs ultra-thin solid-state electrolyte layers (5-50 micrometers, preferably 10-30 micrometers) that function as flexible yet mechanically stable films. This thin-film approach reduces the lithium ion conduction path while maintaining structural integrity through careful material selection and composite structure design, directly resolving the contradiction between thickness for mechanical stability and thinness for power capability.
Solution Approach 2:
The electrolyte layer is constructed as a composite material system combining solid-state electrolyte with porous scaffold structures and interfacial modification layers. This composite approach enhances mechanical stability without requiring increased thickness, as the composite structure provides both structural support and efficient ion transport pathways, simultaneously addressing mechanical stability and power capability requirements.
2Quantity of substance
If solid-state electrolyte layers are made thinner to improve energy density, then energy density is improved, but mechanical properties deteriorate and reliability decreases
Solution Approach 1:
The patent successfully implements ultra-thin electrolyte layers (5-50 micrometers) that maintain both mechanical reliability and high energy density. The thin-film design reduces the volume occupied by the electrolyte, increasing overall energy density, while the film's structural design and material composition ensure sufficient mechanical strength and reliability for practical application.
Solution Approach 2:
The composite structure of the electrolyte layer, combining multiple functional components in a layered architecture, provides enhanced mechanical properties despite the reduced overall thickness. This composite design ensures reliability through distributed stress management and improved interfacial bonding, while the thin total thickness maintains high energy density.
3Temperature
If conventional solid-state electrolytes are used, then high temperature stability is achieved, but they are suitable only for low currents which limits power capability
Solution Approach 1:
The patent modifies key parameters of the solid-state electrolyte system, including reducing layer thickness from conventional scales to 5-50 micrometers, optimizing porosity (30-70%), and adjusting compositional ratios. These parameter changes enable the electrolyte to maintain high temperature stability while achieving superior ionic conductivity that supports high current densities, thereby simultaneously improving temperature stability and power capability.
Solution Approach 2:
The composite electrolyte structure combines materials with complementary properties, where certain components provide high-temperature stability while others enhance ionic conductivity for high-power application. This material composition strategy allows the electrolyte to function reliably at elevated temperatures while supporting the high currents necessary for power-intensive applications.
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 solution results in improved power capability, temperature tolerance, and safety for lithium-ion batteries, enabling higher energy density and superior performance across a wider range of conditions.
Implementation Method 1
a solution-processable solid-state electrolyte that at least partially fills pores of the porous scaffold
Implementation Method 2
The electrolyte is suitable for conducting lithium ions between the electrodes
Data Source
AI summary
An electrochemical cell that includes a first electrode, a second electrode, and an electrolyte layer that is disposed between the first electrode and the second electrode is provided. The electrolyte layer includes a porous scaffold having a porosity greater than or equal to about 50 vol. % to less than or equal to about 90 vol. %, and a solution-processable solid-state electrolyte that at least partially fills the pores of the porous scaffold. The porous scaffold is defined by a plurality of fibers having an average diameter greater than or equal to about 0.01 micrometer to less than or equal to about 10 micrometers and an average length greater than or equal to about 1 micrometer to less than or equal to about 20 micrometers. The solution-processable solid-state electrolyte includes is selected from the group consisting of: sulfide-based solid-state particles, halide-based solid-state particles, hydride-based solid-state particles, and combinations thereof.