How to Build Solid-State Batteries with Tiny Holes for Better Electrolyte
This patent describes a method for manufacturing solid-state batteries by punching small holes through battery electrodes and then filling these holes with a liquid that hardens into a solid electrolyte, aiming for more efficient power delivery.
Original patent title: “Solid state battery with uniformly distributed electrolyte, and methods of fabrication relating thereto”
This patent describes a method for manufacturing solid-state batteries by punching small holes through battery electrodes and then filling these holes with a liquid that hardens into a solid electrolyte, aiming for more efficient power delivery. Granted to GM Global Technology Operations in 2024 with 19 claims and 2 forward citations, and it is expected to expire in 2041.
Coverage
What does this patent actually cover?
The patent outlines a method for creating a solid-state electrochemical cell with a uniformly distributed solid-state electrolyte. First, solid-state electrodes are prepared, consisting of a 'solid-state electroactive material layer' next to a 'current collector' (ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1). Next, a 'plurality of apertures' (many small holes) are punched continuously through both the electroactive material layer and the current collector (Claim 1). These electrodes are then soaked in a 'solid-state electrolyte precursor solution,' a liquid that fills all the punched holes and any other tiny gaps or pores within the electrodes (Claim 1). Finally, the electrodes are heated, causing the liquid precursor solution to solidify and form the 'distributed solid-state electrolyte' throughout the battery structure (Claim 1). For example, this process could be used to ensure the solid electrolyte in an electric vehicle battery is evenly spread, improving its ability to store and release energy.
The gap
What does this patent NOT cover?
- Does not cover solid-state battery manufacturing methods that do not involve punching apertures through the electrodes.
- Does not cover batteries where the electrolyte is formed without first impregnating the electrodes with a liquid precursor solution.
- Does not cover liquid electrolyte batteries, as it specifically focuses on solid-state electrolytes.
- Does not cover methods where apertures are created but do not extend continuously through both the electroactive material layer and the current collector.
- Does not cover solid-state batteries where the electrolyte is applied as a pre-formed solid layer without subsequent impregnation and solidification.
- Does not cover heating temperatures outside the range of about 50° C. to about 300° C. for solidifying the precursor solution.
These exclusions are unique to PatentBrief — derived from the actual claim language, not patent-office boilerplate.
Key facts
What made this novel
The noveltynoveltyThe requirement that an invention be different from anything publicly known before its priority date.Read more → lies in combining physical apertures (holes) punched through the electrode structure with a liquid precursor impregnation and subsequent solidification. This ensures the solid electrolyte is deeply and uniformly distributed within and through the electrode, rather than merely coated on its surfaces, which enhances ion transport.
The Patent Drawing
Schematic visualization of the patent's claim structure. Hand-drawn diagrams in progress for each landmark patent.
Where you've seen this
Real-world examples
Next-generation electric vehicle batteries
High-capacity grid energy storage systems
Advanced portable electronics
Aerospace and defense applications requiring high-density power
Why it matters
The bigger picture
Solid-state batteries are a key area of research because they promise higher energy density and improved safety compared to traditional lithium-ion batteries that use liquid electrolytes. Achieving uniform distribution of the solid electrolyte is critical for the battery's performance, longevity, and fast charging capabilities. This method aims to solve a significant manufacturing challenge in solid-state battery development, which is ensuring good contact and efficient ion flow throughout the solid components.
Filed
December 6, 2021
Granted
March 26, 2024
Market context
Who's building on this
Companies in this space
GM Global Technology Operations LLC, the assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more →, is actively developing solid-state battery technology, particularly for electric vehicles. Other major automotive companies like Toyota, Volkswagen, and startups such as QuantumScape and Solid Power are also heavily invested in advancing solid-state battery manufacturing and performance.
Market impact
This manufacturing method could lead to more reliable and higher-performing solid-state batteries, potentially accelerating their widespread adoption in electric vehicles and grid storage. By addressing a critical manufacturing challenge related to electrolyte distribution, it could enable new product lines with improved safety, faster charging, and extended range, impacting the competitive landscape in the energy storage sector.
Claim 1 — Plain English
What this patent covers
The patent outlines a method for creating a solid-state electrochemical cell with a uniformly distributed solid-state electrolyte. First, solid-state electrodes are prepared, consisting of a 'solid-state electroactive material layer' next to a 'current collector' (Claim 1). Next, a 'plurality of apertures' (many small holes) are punched continuously through both the electroactive material layer and the current collector (Claim 1). These electrodes are then soaked in a 'solid-state electrolyte precursor solution,' a liquid that fills all the punched holes and any other tiny gaps or pores within the electrodes (Claim 1). Finally, the electrodes are heated, causing the liquid precursor solution to solidify and form the 'distributed solid-state electrolyte' throughout the battery structure (Claim 1). For example, this process could be used to ensure the solid electrolyte in an electric vehicle battery is evenly spread, improving its ability to store and release energy.
The clever bit
The novelty lies in combining physical apertures (holes) punched through the electrode structure with a liquid precursor impregnation and subsequent solidification. This ensures the solid electrolyte is deeply and uniformly distributed within and through the electrode, rather than merely coated on its surfaces, which enhances ion transport.
What it does not cover
- Does not cover solid-state battery manufacturing methods that do not involve punching apertures through the electrodes.
- Does not cover batteries where the electrolyte is formed without first impregnating the electrodes with a liquid precursor solution.
- Does not cover liquid electrolyte batteries, as it specifically focuses on solid-state electrolytes.
- Does not cover methods where apertures are created but do not extend continuously through both the electroactive material layer and the current collector.
- Does not cover solid-state batteries where the electrolyte is applied as a pre-formed solid layer without subsequent impregnation and solidification.
- Does not cover heating temperatures outside the range of about 50° C. to about 300° C. for solidifying the precursor solution.
Patent timeline
Application submitted to the patent office
Application published, typically 18 months after filing
Patent officially issued
Patent enters public domain
PatentBrief Score
Impact Score
Moderate
Citation count
10/40
Early citations
Claim breadth
13/20
Broad claimsclaimsThe numbered statements at the end of a patent that legally define what the inventor owns.Read more →
Recency
20/20
Granted within 5 years
Assignee scale
0/20
Independent or smaller assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more →
PatentBrief Impact Score — based on citation count, claim breadth, recency, and assignee scale. Not a legal assessment.
Heuristic Value Estimate
What this patent might be worth
$82K – $262K
Midpoint $164K · 15.4 yr remaining · industry ×1.4
Heuristic only — blends forward/backward citation counts, claim scope, time remaining, litigation history, and CPC-derived industry baseline. Real valuations need a professional appraisal.
Claim text not yet imported for this patent
The original legal language
Original claims
19 claims as filed with the patent office.
Concepts involved
Citations
Patent lineage
Cite this patent
Liu, H., Lu, Y., Li, Z., Wu, M., & Que, X. (2024). How to Build Solid-State Batteries with Tiny Holes for Better Electrolyte (U.S. Patent No. 11,942,620). U.S. Patent and Trademark Office. https://patentbrief.org/patent/us/11942620/solid-state-battery-with-uniformly-distributed-electrolyte-and-methods-of-fabric
Auto-generated from the patent record. Double-check author order and the issue date against the official USPTO document before submitting.
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Common Questions
Frequently Asked Questions
What does How to Build Solid-State Batteries with Tiny Holes for Better Electrolyte cover?
This patent describes a method for manufacturing solid-state batteries by punching small holes through battery electrodes and then filling these holes with a liquid that hardens into a solid electrolyte, aiming for more efficient power delivery.
Who owns patent US 11942620?
GM Global Technology Operations owns this patent, granted in 2024.
When does this patent expire?
This patent is expected to expire on December 6, 2041, when the invention enters the public domain.
What is patent US 11942620 cited by?
This patent has been cited by 2 later patents that build on its ideas.
What problem does this patent solve?
Solid-state batteries are a key area of research because they promise higher energy density and improved safety compared to traditional lithium-ion batteries that use liquid electrolytes. Achieving uniform distribution of the solid electrolyte is critical for the battery's performance, longevity, and fast charging capabilities. This method aims to solve a significant manufacturing challenge in solid-state battery development, which is ensuring good contact and efficient ion flow throughout the solid components.
What does this patent NOT cover?
Does not cover solid-state battery manufacturing methods that do not involve punching apertures through the electrodes.
Same assignee
More from GM Global Technology Operations
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