Hybrid solid state electrolyte

Patent metadata

Field	Value
Publication number	US-12368185-B2
Application number	US-201917414645-A
Country	US
Kind code	B2
Filing date	Dec 19, 2019
Priority date	Dec 19, 2018
Publication date	Jul 22, 2025
Grant date	Jul 22, 2025

Abstract

The present disclosure concerns a solid state electrolyte for providing an ion conductive connection between a negative and positive electrode in a battery, the solid state electrolyte comprising: an ion conductive matrix comprising a polymer, and a metal salt dispersed in the ion conductive matrix, and a first ceramic material, wherein at least one of the faces of the ion conductive matrix for connecting to the negative or positive electrode, is infiltrated with the first ceramic material to form a first, hybrid interface layer.

First claim

The invention claimed is:

1. A solid state electrolyte for providing an ion conductive connection between a negative and positive electrode in a battery, the solid state electrolyte comprising:
a continuous ion conductive matrix comprising a polymer,
a metal salt dispersed in the continuous ion conductive matrix, and
a first ceramic material,
wherein at least one of a first face of the continuous ion conductive matrix and a second face of the continuous ion conductive matrix, configured for connecting to the negative electrode or positive electrode, is infiltrated with the first ceramic material to form a first hybrid interface layer between at least one of the negative electrode and the positive electrode in the battery and the continuous ion conductive matrix, and
wherein a concentration of the first ceramic material, at the first face and the second face of the continuous ion conductive matrix, is greater than a concentration of the first ceramic material at a remainder of the continuous ion conductive matrix that is not part of the first face of the continuous ion conductive matrix and the second face of the continuous ion conductive matrix.

2. The solid state electrolyte according to claim 1 , wherein both the first face and the second face of the continuous ion conductive matrix, configured for connecting to the electrodes, are infiltrated with a ceramic material to form a first hybrid interface layer and a second hybrid interface layer.

3. The solid state electrolyte according to claim 1 , wherein one or more of the first face and the second face of the continuous ion conductive matrix is provided with a first capping layer, wherein the first capping layer comprises one or more materials taken from the group consisting of:
an ion conductive ceramic material, and
a ceramic material that forms an ion conductive material from a reaction between the ceramic material and a negative electrode material.

4. The solid state electrolyte according to claim 3 , wherein the continuous ion conductive matrix is:
provided with the first ceramic capping at a face for connecting with a negative electrode material, and
impregnated with a second ceramic material at a face for interfacing with a positive electrode material.

5. The solid state electrolyte according to claim 3 , wherein the continuous ion conductive matrix is:
provided with the first ceramic capping at a face for connecting with a positive electrode material, and
impregnated with a second ceramic material at a face for interfacing with a negative electrode material.

6. The solid state electrolyte according to claim 1 , wherein both the first face and the second face of the continuous ion conductive matrix, configured for connecting to the electrodes, are provided with a respective capping layer.

7. A multi-layered solid state electrolyte formed by a stack of solid state electrolyte layers according to claim 1 .

8. A battery comprising a solid state electrolyte, according to claim 1 , provided between a positive and a negative electrode.

9. The battery according to claim 8 , wherein:
the negative electrode comprises lithium,
the metal salt comprises lithium ions, and
a ceramic coating facing the negative electrode, wherein the ceramic coating comprises a lithiophilic material.

10. A process for manufacturing a solid state electrolyte for providing an ion conductive connection between a negative and positive electrode in a battery, the solid state electrolyte comprising:
a continuous ion conductive matrix comprising a polymer,
a metal salt dispersed in the continuous ion conductive matrix, and
a first ceramic material,
wherein at least one of a first face of the continuous ion conductive matrix and a second face of the continuous ion conductive matrix, configured for connecting to the negative electrode or positive electrode, is infiltrated with the first ceramic material to form a first hybrid interface layer between at least one of the negative electrode and positive electrodes in the battery and the continuous ion conductive matrix;
wherein the process comprises:
providing the continuous ion conductive matrix comprising a polymer and dispersed metal salt;
feeding the continuous ion conductive matrix to a station for impregnating the first hybrid interface layer with a ceramic material; and
exposing a first face of the continuous ion conductive matrix with a vapor phase ceramic precursor material using a chemical vapor impregnation method,

wherein the vapor phase ceramic precursor material:
infiltrates into the continuous ion conductive matrix, and
reacts with a co-reactant to form a hybrid interface layer forming an interface layer between at least one of a negative electrode and a positive electrode in a battery and the continuous ion conductive matrix comprised therein.

11. The process according to claim 10 wherein the chemical vapor impregnation method is any one or more methods selected from the group consisting of:
chemical vapor deposition, physical vapor deposition,
atomic layer deposition, and
spatially resolved ALD.

12. The process according to claim 10 , comprising providing a ceramic capping layer.

13. The process according to claim 12 , wherein one or more of continuous ion conductive hybrid interface layer forming or capping layer providing are performed on a second face of the continuous ion conductive matrix.

14. The process according to claim 10 further comprising depositing a positive electrode material and negative electrode material.

15. The process according to claim 11 , wherein impregnation depth of the vapor phase ceramic precursor material is controlled by one or more of the group consisting of:
exposure concentration,
exposure pressure,
exposure temperature,
exposure time, and
delay time between consecutive exposures.

16. The solid state electrolyte according to claim 2 , wherein the ceramic material of the second hybrid interface layer comprises a second ceramic material that differs from the ceramic material of the first hybrid interface layer.

17. The solid state electrolyte according to claim 2 , wherein the ceramic material of the second hybrid interface layer is the same as the ceramic material of the first hybrid interface layer.

18. The process according to claim 10 , wherein a concentration of the first ceramic material, at the first face and the second face of the continuous ion conductive matrix, is greater than a concentration of the first ceramic material at a remainder of the continuous ion conductive matrix that is not part of the first face of the continuous ion conductive matrix and the second face of the continuous ion conductive matrix.

Assignees

• TNO

Inventors

• Tulodziecki Michal
• Unnikrishnan Sandeep
• Haverkate Lucas Augustinus

Classifications

• H01M2300/0094

  in the form of layered products, e.g. coatings · CPC title

• H01M2300/0091

  in the form of mixtures · CPC title

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M50/434

  Ceramics · CPC title

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title