# US 11,631,890 B2 · All solid-state lithium-ion battery produced by pressure-aided co-curing

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- Number: US 11,631,890 B2
- Document ID: US11631890B2
- Status: Granted
- Kind: B2
- Application number: 17/313,992
- Filed: 2021-05-06
- Published: 2022-11-10
- Granted: 2023-04-18
- Earliest claimed: 2021-05-06
- Assignees: Solid Energies Inc.
- Applicants: Solid Energies Inc.
- Inventors: Zhigang Lin; Tianyu Meng
- Web page: https://patentgrep.com/patent/US11631890B2

## CPC

- H01M 10/0562: Solid materials
- H01M 4/0404: {by coating on electrode collectors}
- H01M 4/043: {involving compressing or compaction}
- H01M 10/0427: {Button cells}
- H01M 10/0481: {Compression means other than compression means for stacks of electrodes and separators}
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H01M 10/0565: Polymeric materials, e.g. gel-type or solid-type
- H01M 50/446: Composite material consisting of a mixture of organic and inorganic materials
- H01M 10/04: Construction or manufacture in general (H01M10/058, H01M10/12, H01M10/28, H01M10/38 take precedence)
- H01M 50/105: Pouches or flexible bags
- H01M 50/109: of button or coin shape
- H01M 50/414: Synthetic resins, e.g. thermoplastics or thermosetting resins
- H01M 50/434: Ceramics
- H01M 2300/0071: Oxides
- H01M 2300/0077: based on zirconium oxide
- H01M 2300/0082: Organic polymers
- H01M 2300/0091: in the form of mixtures
- Y02E 60/10: Energy storage using batteries
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

In solid-state lithium-ion battery cells, electrolyte-infiltrated composite electrode includes an electrolyte component consisting of polymer matrix with ceramic nanoparticles embedded in the matrix to form networking structure of electrolyte. The networking structure establishes effective lithium-ion transport pathway in the electrode. Electrolyte-infiltrated composite electrode sheets and solid electrolyte membranes can be used in all solid-state lithium electrochemical pouch and coin cells. Solid-state lithium-ion battery is fabricated by: (a) providing an anode layer; (b) providing a cathode layer; (c) positioning a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer to form a laminar battery assembly; (d) applying pressure to the laminar battery assembly; and (e) heating the laminar battery assembly. Pressure-aided co-curing strengthens the contacts between the electrodes and the solid electrolyte membrane thus creating stable electrode-membrane interfaces with fewer porous regions. Lithium electrochemical cells and batteries exhibit excellent rate performance and outstanding stability over wide temperature range.

## Claims

### Claim 1

A method of fabricating a solid-state lithium-ion battery comprising:
(a) providing an anode layer;
(b) providing a cathode layer;
(c) positioning a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer to form a laminar battery assembly;
(d) applying pressure to the laminar battery assembly by
applying a pressure of 100 to 80,000 psi to the pouch for 1 to 100 min; and
(e) heating the laminar battery assembly.

### Claim 2

A method of fabricating a solid-state lithium-ion battery comprising:
(a) providing an anode layer;
(b) providing a cathode layer;
(c) positioning a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer to form a laminar battery assembly;
(d) applying pressure to the laminar battery assembly; and
(e) heating the laminar battery assembly by heating the pouch to a temperature of 80 to 280° C. for 1 to 100 min.

### Claim 3 (depends on 1)

The method of claim 1 wherein the laminar battery assembly is encased in metal casing comprising a positive contact surface and a negative contact surface wherein the positive contact surface is substantially co-extensive and extends parallel to the negative contact surface.

### Claim 4

A method of fabricating a solid-state lithium-ion battery comprising:
(a) providing an anode layer;
(b) providing a cathode layer;
(c) positioning a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer to form a laminar battery assembly which is encased in metal casing comprising a positive contact surface and a negative contact surface wherein the positive contact surface is substantially co-extensive and extends parallel to the negative contact surface;
(d) applying pressure to the laminar battery assembly by applying a pressure of 100 to 80,000 psi to the metal casing for 1 to 100 min; and
(e) heating the laminar battery assembly.

### Claim 5

A method of fabricating a solid-state lithium-ion battery comprising:
(a) providing an anode layer;
(b) providing a cathode layer;
(c) positioning a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer to form a laminar battery assembly which is encased in metal casing comprising a positive contact surface and a negative contact surface wherein the positive contact surface is substantially co-extensive and extends parallel to the negative contact surface;
(d) applying pressure to the laminar battery assembly; and
(e) heating the laminar battery assembly by heating the metal casing to a temperature of 80 to 280° C. for 1 to 100 min.

### Claim 6 (depends on 1)

The method of claim 1 wherein step (d) comprises using a flat press.

### Claim 7

A method of fabricating a solid-state lithium-ion battery comprising:
(a) providing an anode layer;
(b) providing a cathode layer;
(c) positioning a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer to form a laminar battery assembly;
(d) applying pressure to the laminar battery assembly by using a pressurized liquid-filled chamber; and
(e) heating the laminar battery assembly.

### Claim 8

A method of fabricating a coin cell that comprises:
(a) providing a first metal pole having a first planar exterior surface;
(b) providing a second metal pole having a second planar exterior surface;
(c) positioning a unit cell between the first and second metal poles wherein the unit cell comprises (i) an anode layer (ii) cathode layer and (iii) a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer;
(d) applying pressure to compress the first and second metal poles, wherein the first and second poles are electronically separated by an insulating material; and
(e) heating the first and second metal poles.

### Claim 9 (depends on 8)

The method of claim 8 wherein the ceramic-polymer composite electrolyte membrane comprises: (i) a polymer matrix, (ii) ceramic nanoparticles with diameters that range from 10 to 2000 nm that are distributed in the polymer matrix, (iii) a plasticizer and (iv) a lithium salt, wherein the ceramic nanoparticles are selected from the group consisting of ceramic materials which has the basic formula Li7La3Zr2O12 (LLZO) and derivatives thereof wherein at least one of Al, Ta or Nb is substituted in Zr sites of the Li7La3Zr2O12.

### Claim 10

A solid-state lithium-ion battery that is fabricated by:
(a) providing an anode layer;
(b) providing a cathode layer;
(c) positioning a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer to form a laminar battery assembly wherein the ceramic-polymer composite electrolyte membrane comprises: (i) a polymer matrix, (ii) ceramic nanoparticles with diameters that range from 10 to 2000 nm that are distributed in the polymer matrix, (iii) a plasticizer and (iv) a lithium salt, wherein the ceramic nanoparticles are selected from the group consisting of ceramic materials which has the basic formula Li7La3Zr2O12 (LLZO) and derivatives thereof wherein at least one of Al, Ta or Nb is substituted in Zr sites of the Li7La3Zr2O12;
(d) applying pressure to the laminar battery assembly; and
(e) heating the laminar battery assembly.

### Claim 11 (depends on 10)

The battery of claim 10 wherein the laminar battery assembly is sealed in a flexible shell in the form of a pouch.

### Claim 12

A solid-state lithium-ion battery that is fabricated by:
(a) providing an anode layer;
(b) providing a cathode layer;
(c) positioning a ceramic-polymer composite electrolyte membrane between the anode layer and the cathode layer to form a laminar battery assembly;
(d) applying pressure to the laminar battery assembly; and
(e) heating the laminar battery assembly, wherein the laminar battery assembly is in the form of a coin cell.