IP Library › Granted Patent US 11,749,801

Granted Patent B2

US 11,749,801 · App. 17/397,190 · Granted Sep 5, 2023

All solid state battery and manufacturing method

Inventors: Sangwook Han (Ansan-si, KR); Hannah Song (Ansan-si, KR); Kyeong Wi Park (Suwon-si, KR)

Assignees: Hyundai Motor Company; Kia Corporation

H01M4/5815 H01M4/0404 H01M4/661 H01M4/663 H01M4/666 H01M10/058 H01M10/0562 H01M2004/027 H01M2004/028 H01M2300/0068

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Quick Facts

Patent No.: US 11,749,801
App. No.: 17/397,190
Granted: Sep 5, 2023
Kind: B2

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Abstract

An embodiment all solid state battery includes a sulfide-based solid electrolyte layer, a negative electrode comprising a negative active material layer stacked on a first surface of the solid electrolyte layer and a negative buffer layer stacked on a first surface of the negative active material layer, and a positive electrode comprising a positive active material layer stacked on a second surface of the solid electrolyte layer and a positive buffer layer stacked on a second surface of the positive active material layer.

Claims (88)

1. An all solid state battery comprising:

a sulfide-based solid electrolyte layer;

a negative electrode comprising:

a negative active material layer disposed on a first surface of the solid electrolyte layer;

a negative buffer layer disposed on a first surface of the negative active material layer, the negative buffer layer comprising a mixture of a first sulfide-based material, a first conductive material, and a second binder, wherein the negative buffer layer has a different composition than the negative active material layer;

a negative primer layer disposed on a first surface of the negative buffer layer, wherein the negative buffer layer has a degree of softness that is higher than that of the negative primer layer; and

a negative current collector layer having a second surface disposed on a first surface of the negative primer layer, the second surface of the negative current collector layer having a surface roughness; and

a positive electrode comprising:

a positive active material layer disposed on a second surface of the solid electrolyte layer;

a positive buffer layer disposed on a second surface of the positive active material layer the positive buffer layer comprising a mixture of the first sulfide-based material, the first conductive material, and the second binder without an active material, wherein the positive buffer layer has a different composition than the positive active material layer;

a positive primer layer disposed on a second surface of the positive buffer layer, wherein the positive buffer layer has a degree of softness that is higher than that of the positive primer layer; and

a positive current collector layer having a first surface disposed on a second surface of the positive primer layer, the first surface of the positive current collector layer having a surface roughness.

2. The all solid state battery of claim 1 , wherein the negative primer layer comprises a mixture of a carbon-based conductive material and a first binder; and

wherein the negative active material layer comprises a mixture of a second sulfide-based material, a negative electrode active material, a second conductive material, and a third binder, wherein the negative active material layer is in contact with the solid electrolyte layer.

3. The all solid state battery of claim 1 , wherein the negative current collector layer comprises at least one of copper, stainless steel, titanium, iron, or nickel.

4. The all solid state battery of claim 2 , wherein the mixture of the carbon-based conductive material and the first binder of the negative primer layer has a ratio of 7:3 to 9-5:0.5.

5. The all solid state battery of claim 1 , wherein the mixture of the negative buffer layer comprises the first sulfide-based material in a range of 60 wt % or more and 90 wt % or less, the first conductive material in a range of 9 wt % or more and 30 wt % or less, and the second binder in a range of 1 wt % or more and 10 wt % or less, based on 100 wt % of a total weight.

6. The all solid state battery of claim 1 , wherein the negative buffer layer has a same ionic conductivity and electronic conductivity as the negative active material layer.

7. The all solid state battery of claim 2 , wherein the mixture of the negative active material layer comprises the second sulfide-based material in a range of 8 wt % to 30 wt %, the negative active material layer in a range of 60 wt % to 90 wt %, the second conductive material in a range of 1 wt % to 10 wt %, and the third binder in a range of 1 wt % to 10 wt %, based on 100 wt % of a total weight.

8. The all solid state battery of claim 1 , wherein the positive primer layer comprises a mixture of a carbon-based conductive material and a first binder; and

wherein the positive active material layer comprises a mixture of a second sulfide-based material, a positive electrode active material, a second conductive material, and a third binder, wherein the positive active material layer is in contact with the solid electrolyte layer.

9. The all solid state battery of claim 7 , wherein the positive current collector layer comprises at least one of stainless steel, titanium, iron, nickel, aluminum, or chromium.

10. The all solid state battery of claim 8 , wherein the mixture of the carbon-based conductive material and the first binder of the positive primer layer has a ratio of 7:3 to 9-5:0.5.

11. The all solid state battery of claim 1 , wherein the mixture of the positive buffer layer comprises the first sulfide-based material in a range of 60 wt % or more and 90 wt % or less, the first conductive material in a range of 9 wt % or more and 30 wt % or less, and the second binder in a range of 1 wt % or more and 10 wt % or less, based on 100 wt % of a total weight.

12. The all solid state battery of claim 1 , wherein the positive buffer layer has a same ionic conductivity and electronic conductivity as the positive active material layer.

13. The all solid state battery of claim 8 , wherein the mixture of the positive active material layer comprises the second sulfide-based material in a range of 8 wt % to 30 wt %, the positive active material layer in a range of 60 wt % to 90 wt %, the second conductive material in a range of 1 wt % to 10 wt %, and the third binder in a range of 1 wt % to 10 wt %, based on 100 wt % of a total weight.

14. A method of manufacturing the all solid state battery of claim 1 , the method comprising:

forming the negative electrode;

forming the sulfide-based solid electrolyte layer on a second surface of the negative electrode;

forming the positive electrode and

bonding the positive electrode to the second surface of the solid electrolyte layer.

15. The method of claim 14 , wherein forming the negative electrode comprises:

forming the surface roughness on the second surface of a negative current collector through a surface treatment;

forming the negative primer layer on the negative current collector through wet coating;

forming the negative buffer layer on the negative primer layer through wet coating;

forming the negative active material layer on the negative buffer layer; and

rolling the negative current collector, the negative primer layer, the negative buffer layer, and the negative active material layer which are stacked.

16. The method of claim 15 , wherein the sulfide-based solid electrolyte layer is formed on the second surface of the negative electrode through wet coating.

17. The method of claim 14 , wherein forming the positive electrode comprises:

forming surface roughness on the second surface of a positive current collector through a surface treatment;

forming the positive primer layer on a first surface of on the positive current collector through wet coating;

forming the positive buffer layer on the positive primer layer;

forming the positive active material layer on the positive buffer layer; and

rolling the positive current collector, the positive primer layer, the positive buffer layer, and the positive active material layer which are stacked.

18. The method of claim 14 , wherein bonding the positive electrode comprises:

inverting the positive electrode in a vertical direction and contacting the sulfide-based solid electrolyte layer with the positive active material layer of the positive electrode; and

rolling the negative electrode, the sulfide-based solid electrolyte layer, and the positive electrode.

19. An all solid state battery comprising:

a positive current collector layer;

a positive primer layer overlying the positive current collector layer;

a positive buffer layer overlying the positive primer layer;

a positive active material layer overlying the positive buffer layer;

a sulfide-based solid electrolyte layer overlying the positive active material layer;

a negative active material layer overlying the sulfide-based solid electrolyte layer;

a negative buffer layer overlying the negative active material layer;

a negative primer layer overlying the negative buffer layer; and

a negative current collector layer overlying the negative primer layer;

wherein the negative buffer layer comprises a mixture of a first sulfide-based material, a first conductive material, and a second binder;

wherein the mixture of the negative buffer layer does not include any active material;

wherein the negative buffer layer has a degree of softness that is higher than that of the negative primer layer;

wherein a surface of the negative current collector layer adjacent the negative primer layer has a surface roughness;

wherein the positive buffer layer comprises a mixture of the first sulfide-based material, the first conductive material, and the second binder;

wherein the positive buffer layer has a degree of softness that is higher than that of the positive primer layer;

wherein first surface of the positive current collector layer adjacent the negative primer has a surface roughness;

wherein the negative primer layer comprises a mixture of a carbon-based conductive material and a first binder;

wherein the mixture of the positive buffer layer does not include any active material;

wherein the negative active material layer comprises the second sulfide-based material in a range of 8 wt % to 30 wt %, the negative active material layer in a range of 60 wt % to 90 wt %, the second conductive material in a range of 1 wt % to 10 wt %, and the third binder in a range of 1 wt % to 10 wt %, based on 100 wt % of a total weight.

20. An all solid state battery comprising: