Systems and Methods of Making Solid-State Batteries and Associated Solid-State Battery Cathodes
Various embodiments and methods related to solid-state battery and associated solid-state battery cathodes are presented. The solid-state battery may include a solid-state battery cathode, a solid-state battery anode, and a solid electrolyte separator. The solid-state battery cathode may include an active material. The active material may include a plurality of particles characterized by a D50 diameter from about 10 μm to about 200 μm. The plurality of particles may include a microstructure formed from a plurality of crystalline grains. In some embodiments, the plurality of crystalline grains may be characterized by a D50 diameter of from about 2 nm to about 25 nm. The solid-state battery cathode may also include a solid-state interfacial coating coated on to the plurality of particles. The solid-state interfacial coating may include a crystalline material.
1 . A solid-state battery comprising:
a solid-state battery cathode comprising:
an active material comprising a plurality of particles provided to form the solid-state battery cathode, wherein:
the plurality of particles are characterized by a D50 diameter from about 10 μm to about 200 μm; and
the plurality of particles comprise a microstructure formed from a plurality of crystalline grains; and
a solid-state interfacial coating comprising a crystalline material, wherein the solid-state interfacial coating is coated on to the plurality of particles;
a solid-state battery anode; and
a solid electrolyte separator positioned between the solid-state battery cathode and the solid-state battery anode to form the solid-state battery.
2 . The solid-state battery of claim 1 , wherein the solid-state battery anode comprises:
a solid electrolyte powder, and
a plurality of anode particles mixed with the solid electrolyte powder to form the solid-state battery anode.
3 . The solid-state battery of claim 1 , wherein the plurality of crystalline grains are characterized by a D50 diameter of from about 2 nm to about 25 nm.
4 . The solid-state battery of claim 1 , wherein the solid-state battery has an initial capacity of at or above 125 mAh/g at 0.1 C and a rate performance of at or above 75% at a C-rate of 2 C and 0.1 C.
5 . A solid-state battery cathode comprising:
a solid electrolyte powder;
an active material comprising a plurality of particles mixed with the solid electrolyte powder to form a solid-state battery cathode, wherein:
the plurality of particles are characterized by a D50 diameter from about 10 μm to about 200 μm; and
the plurality of particles comprise a microstructure formed from a plurality of crystalline grains; and
a solid-state interfacial coating comprising a crystalline material, wherein the solid-state interfacial coating is coated on to the plurality of particles to reduce interfacial reactivity between the plurality of the particles and the solid electrolyte powder within the solid-state battery cathode.
6 . The solid-state battery cathode of claim 5 , wherein the plurality of crystalline grains are characterized by a diameter from about 2 μm to about 25 μm.
7 . The solid-state battery cathode of claim 5 , wherein the plurality of particles are characterized by a spherical shape.
8 . The solid-state battery cathode of claim 5 , wherein the solid-state interfacial coating comprises graphene.
9 . The solid-state battery cathode of claim 5 further comprising a plurality of conductive fibers, wherein the plurality of conductive fibers are interspersed between the plurality of particles within the solid-state battery cathode.
10 . The solid-state battery cathode of claim 9 , wherein the plurality of conductive fibers comprise vapor grown carbon fibers.
11 . The solid-state battery cathode of claim 5 , wherein the solid electrolyte powder comprises a sulfur-based solid electrolyte.
12 . A method of making a solid-state battery cathode, the method comprising:
providing an active material;
filtering the active material to form a plurality of particles characterized by a D50 diameter from about 10 μm to about 200 μm;
coating the plurality of particles with an interfacial coating;
forming a plurality of crystalline grains within the plurality of particles by heating the plurality of particles to a temperature from about 350° C. to about 600° C.;
mixing a solid electrolyte powder with the plurality of particles to form a dry cathode mixture; and
pressing the dry cathode mixture to form the solid-state battery cathode.
13 . The method of making the solid-state battery cathode of claim 12 , wherein mixing the solid electrolyte powder with the plurality of particles comprises:
dissolving the solid electrolyte powder in an electrolyte solvent to form an electrolyte solution;
mixing the plurality of particles and the electrolyte solution to form a cathode solution;
drying the cathode solution to form a cathode composite; and
pressing the cathode composite to form the solid-state battery cathode.
14 . The method of claim 12 , wherein heating the plurality of particles comprises calcination.
15 . The method of claim 12 , wherein the plurality of crystalline grains are characterized by a diameter of from about 20 nm to about 150 nm.
16 . The method of claim 13 , wherein the electrolyte solution comprises anhydrous N-methylformamide.
17 . The method of claim 13 , wherein a concentration of the solid electrolyte powder in the electrolyte solution is from about 15 mol % to about 30 mol %.
18 . The method of claim 13 , wherein drying the cathode solution comprises maintaining the cathode solution at a temperature of from about 100° C. to 200° C. for about 1 hour to 3 hours under vacuum.
19 . The method of claim 12 , wherein coating the plurality of particles comprises spray coating the plurality of particles in a fluidized bed with a coating solution.
20 . The method of claim 19 , wherein the coating solution comprises LiOH, Zr(t-BuO) 4 , or ethanol.