Multi-layer all solid-state battery coating

Patent metadata

Field	Value
Publication number	US-12537216-B2
Application number	US-202217889547-A
Country	US
Kind code	B2
Filing date	Aug 17, 2022
Priority date	Aug 17, 2022
Publication date	Jan 27, 2026
Grant date	Jan 27, 2026

Abstract

A coating system for a solid-state battery includes a feeder for a first substrate foil, and an electrolyte dispenser between two electrode dispensers. The first electrode dispenser has a first mixture of a first solid active material and a first solid electrolyte therein, and deposits a first electrode layer on the foil. The electrolyte dispenser deposits an electrolyte layer on the first electrode layer. The second electrode dispenser has a second mixture of second solid active material and a second solid electrolyte, and deposits a second electrode layer on the electrolyte layer. A roller provides a second substrate foil downstream of the second electrode dispenser on the second electrode layer to form a layered structure. The system also includes drums for press rolling the layered structure to form a solid-state battery, with the layers being continuously deposited.

First claim

What is claimed is:

1 . A coating system for a solid-state battery comprising:
a feeder providing a first substrate foil; a first electrode dispenser downstream of the feeder having a first mixture of a first solid active material and a first solid electrolyte therein, the first dispenser depositing a first electrode layer on the first substrate foil; an electrolyte dispenser downstream of the first electrode dispenser having a second solid electrolyte therein, the electrolyte dispenser depositing an electrolyte layer on the first electrode layer; a second electrode dispenser downstream of the electrolyte dispenser having a second mixture of a second solid active material and a third solid electrolyte therein, the second electrode dispenser depositing a second electrode layer on the electrolyte layer; a roller providing a second substrate foil downstream of the second electrode dispenser on the second electrode layer to form a layered structure; and drums for press rolling the layered structure to form a solid-state battery, wherein the first electrode dispenser, electrolyte dispenser, and second electrode dispenser continuously and consecutively deposit the first electrode layer, the electrolyte layer, and the second electrode layer therebetween such that the layered structure is formed via continuous and consecutive deposition prior to press-rolling by the drums.

2 . The coating system of claim 1 , wherein the drums are heated for heated press rolling the layered structure.

3 . The coating system of claim 1 , wherein the first electrode dispenser, the electrolyte dispenser, and the second electrode dispenser are housed in a single dispenser head such that the first electrode dispenser is a first electrode nozzle in the single dispenser head, the electrolyte dispenser is an electrolyte nozzle in the single dispenser head, and the second electrode dispenser is a second electrode nozzle in the single dispenser head.

4 . The coating system of claim 1 , wherein the first electrode dispenser, the electrolyte dispenser, and the second electrode dispenser are separate dispenser heads for depositing the first electrode layer, the electrolyte layer, and the second electrode layer, respectively.

5 . The coating system of claim 1 , further comprising at least one coating regulator comprising a bar or blade downstream of the feeder and upstream of the roller.

6 . The coating system of claim 5 , further comprising a first coating regulator downstream of the first electrode dispenser and upstream of the electrolyte dispenser, the first coating regulator configured to perform a predetermined first electrode regulation treatment to the first electrode layer.

7 . The coating system of claim 6 , further comprising a second coating regulator comprising a bar or a blade downstream of the electrolyte dispenser and upstream of the second electrode dispenser, the second coating regulator configured to perform a predetermined electrolyte regulation treatment to the electrolyte layer.

8 . The coating system of claim 7 , further comprising a third coating regulator comprising a bar or a blade downstream of the second electrode dispenser and upstream of the roller, the third coating regulator configured to perform a predetermined second electrode regulation treatment to the second electrode layer.

9 . The coating system of claim 5 , further comprising a first coating regulator comprising a bar or a blade downstream of the first electrode dispenser and upstream of the electrolyte dispenser, the first coating regulator configured to perform a predetermined first electrode regulation treatment to the first electrode layer, and a second coating regulator comprising a bar or a blade downstream of the second electrode dispenser and upstream of the roller, the second coating regulator configured to perform a predetermined second electrode regulation treatment to the second electrode layer.

10 . A coating system for a solid-state battery comprising:
a feeder providing a first substrate foil; an anolyte dispenser downstream of the feeder having a first mixture of anode active material and anode solid electrolyte therein, the anolyte dispenser depositing an anolyte layer on the first substrate foil; an electrolyte dispenser downstream of the feeder having a solid electrolyte material therein, the electrolyte dispenser depositing an electrolyte layer on the anolyte layer; a catholyte dispenser downstream of the feeder having a second mixture of cathode active material and a cathode solid electrolyte therein, the catholyte dispenser depositing a catholyte layer on the electrolyte layer; a roller providing a second substrate foil downstream of the anolyte dispenser, electrolyte dispenser, and catholyte dispenser to form a layered structure; and drums for press rolling the layered structure, wherein the anolyte dispenser, electrolyte dispenser, and catholyte dispenser continuously and consecutively deposit the anolyte layer, electrolyte layer, and catholyte layer, respectively, such that the layered structure is formed via continuous and consecutive deposition prior to roll pressing by the drums.

11 . The coating system of claim 10 , further comprising:
an anolyte regulator comprising a bar or a blade downstream of the anolyte dispenser configured to perform a predetermined anolyte layer regulation treatment to the anolyte layer; and a catholyte regulator comprising a bar or a blade downstream of the catholyte dispenser configured to perform a predetermined catholyte layer regulation treatment to the catholyte layer.

12 . The coating system of claim 11 , wherein the predetermined anolyte layer regulation treatment and predetermined catholyte layer regulation treatment are each thickness-regulated.

13 . The coating system of claim 11 , further comprising:
an electrolyte regulator comprising a bar or a blade downstream of the anode dispenser configured to perform a predetermined electrolyte layer regulation treatment to the electrolyte layer.

14 . The coating system of claim 10 , wherein the anolyte dispenser is upstream of the catholyte dispenser.

15 . A method of producing an all-solid-state battery comprising:
depositing a first electrode layer on a first surface layer of a first substrate foil, the first electrode layer including a first solid active material and a first solid electrolyte material; depositing an electrolyte layer on the first electrode layer, the electrolyte layer including a second solid electrolyte material; depositing a second electrode layer on the electrolyte layer, the second electrode layer including a second solid active material and a third solid electrolyte material; disposing a second substrate foil on the second electrode layer to form a layered structure; and press-rolling the layered structure to form a solid-state cell, wherein the first electrode layer, the electrolyte layer, and the second electrode layer are continuously and consecutively deposited, respectively, such that the layered structure is formed via continuous and consecutive deposition prior to roll pressing by the drums.

16 . The method of claim 15 , further comprising performing a regulation treatment via a bar or a blade to one or more of the first electrode layer, the electrode layer, and the second electrode layer.

17 . The method of claim 16 , wherein the regulation treatment is based on a thickness of the one or more of the first electrode layer, the electrode layer, and the second electrode layer.

18 . The method of claim 15 , wherein t

Assignees

• Ford Global Tech Llc

Inventors

• Pietrasz Patrick
• Kwak Gunho
• Paik Chi

Classifications

• H01M10/0585 Primary

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M10/0562

  Solid materials · CPC title

• H01M4/139

  Processes of manufacture · CPC title

• H01M4/0435

  Rolling or calendering · CPC title

• H01M4/0407

  by coating on an electrolyte layer · CPC title