Thin-Film Solid Electrolyte Body on a Porous Ceramic Support

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Solution Overview

Problem

Existing methods struggle to produce a solid electrolyte with a thin dense body thickness of 100 μm or less due to cracking issues arising from insufficient strength.

Innovation Solution

A method involving the formation of a porous body with open pores, followed by integrating a thin membrane-shaped second ceramic molded body and firing to create a dense body with a thin membrane-shaped solid electrolyte, facilitating the production of a solid electrolyte body and all-solid state battery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a thin dense body with thickness of 100 μm or less is prepared, then the productivity and performance of the all-solid state battery are improved, but the solid electrolyte becomes very difficult to produce due to cracking arising from insufficient strength

Engineering Contradiction:

Improveproduction feasibility of thin solid electrolyteVSAvoidstrength of thin solid electrolyte

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The invention creates a composite structure consisting of a porous body and a dense body integrated together. The porous body acts as a supporting substrate that provides mechanical strength, while the dense body contains the solid electrolyte. This composite structure allows the dense body to be very thin (100 μm or less) without compromising overall strength, as the porous body prevents cracking while maintaining the thin profile needed for high productivity and battery performance.

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

Enables the production of a solid electrolyte body and all-solid state battery with a thin dense body, overcoming cracking issues and enhancing production feasibility.

Implementation Method 1

a step of preparing the porous body by preparing a first molded body and firing the first molded body

Methodology Applied

Scientific EffectFiring:

Implementation Method 2

preparing the dense body containing the solid electrolyte by firing the second molded body

Methodology Applied

Scientific EffectFiring:

Data Source

PatentUS12469874B2Solid electrolyte body, all-solid-state battery, method for producing solid electrolyte body, and method for producing all-solid-state battery

Publication Date: 2025.11.11 JAPAN FINE CERAMICS

AI summary

Provided is a method for easily producing a thin-membrane solid electrolyte body. A molded body (11) of a first ceramic is prepared, and the molded body (11) is fired in a first temperature range to prepare a porous body (110). A thin membrane-shaped molded body (12) composed of a second ceramic containing a solid electrolyte is prepared on at least a part of a surface of the porous body (110). A dense body (120) is prepared by firing the thin membrane-shaped molded body (12). As a result, a solid electrolyte body (1) including the porous body (110) as a support and the dense body (120) of a thin membrane-shaped electrolyte integrally formed with at least a part of the surface of the porous body (110), is produced.