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.

What it 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.

What it doesn't 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.

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.

Why it matters

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.

Real-world examples

• 1.Next-generation electric vehicle batteries
• 2.High-capacity grid energy storage systems
• 3.Advanced portable electronics
• 4.Aerospace and defense applications requiring high-density power