Hyundai's Development in Solid-State Battery Technology

A manufacturing method for all-solid-state batteries that provides dimensional stability and cell performance without ultra-high pressure pressing. The method involves forming electrode members with extended lengths, layering them, then pressing the stack. This prevents deformation during pressing. After pressing, the extended electrode is folded around the shorter one to create the final battery shape. This avoids the damage and cost increases of ultra-high pressure pressing while maintaining performance.

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Lithium metal halide-based solid electrolyte for all-solid-state batteries with improved lithium ion conductivity. The solid electrolyte has a crystal structure different from conventional lithium metal halide-based solid electrolytes. The new crystal structure was discovered using particle swarm optimization (PSO) algorithm to find energetically stable crystal structures. This optimization approach allowed predicting metastable crystal structures that haven't been observed yet but can be synthesized. The resulting new crystal structure provides better lithium ion conductivity compared to conventional lithium metal halide-based solid electrolytes.

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An all-solid-state battery design that can suppress volume expansion during charging and discharging. The battery has a buffer layer sandwiched between the negative electrode current collector and the intermediate layer. This elastic buffer helps minimize volume changes in the battery during charge/discharge cycles compared to conventional all-solid-state batteries without the buffer.

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Solid electrolyte for all-solid-state batteries with improved performance by coating the sulfide-based solid electrolyte particles. The coating contains metal alkoxides. This coating protects the sulfide electrolyte from defects and reactions during manufacturing and operation. It also reduces interfacial resistance between the electrolyte and electrodes. The coated sulfide electrolyte particles are used in the battery along with the coated electrode materials. The coated electrolyte provides better stability, lower resistance, and improved performance compared to uncoated sulfide electrolytes in all-solid-state batteries.

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Solid electrolyte for all-solid-state batteries with excellent moisture stability and a method to make it. The solid electrolyte is a sulfide-based material with a unique composition containing lithium, phosphorus, and halogen elements like bromine and chlorine. The halogen elements improve moisture stability by preventing water molecules from breaking down the sulfur bonds in the electrolyte. The electrolyte can be made by grinding and heat treating specific compounds containing lithium, phosphorus, halogens, and other elements like tin.

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Solid electrolyte for all-solid-state batteries that improves interfacial resistance and stability in all-solid-state batteries. The solid electrolyte contains sulfide-based solid electrolyte particles with a coating layer on their surface that contains metal alkoxides. This coating layer reduces interfacial resistance between the solid electrolyte and other battery components like the cathode. The coating also improves moisture stability of the sulfide-based electrolyte. The coated electrolyte particles are prepared by dispersing the sulfide particles in a solution of metal alkoxides and solvent, removing the solvent, and drying the particles. This provides a method to manufacture sulfide solid electrolytes with improved performance in all-solid-state batteries.

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An all-solid-state battery design that prevents lithium dendrite formation and improves energy density. The battery has a three-layer stack with a self-standing sheet layer sandwiched between the positive and negative electrodes. The sheet layer is composed of two distinct layers with different properties. The inner layer promotes lithium deposition while the outer layer suppresses dendrite growth. This prevents dendrites from penetrating the solid electrolyte and shorting the battery. The dual-layer sheet allows efficient lithium storage without dendrite issues.

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All-solid-state battery that can be charged and discharged at room temperature without degradation. The battery uses a unique construction with a network-structured positive electrode layer instead of conventional conductive additives. This layer is made by treating a carbon nanotube film to create interconnected pores. The pores are filled with positive electrode material. This provides conductivity without adding extra powder that can react with the electrolyte or reduce capacity. The battery stack includes the treated positive electrode, solid electrolyte, intermediate layer, negative electrode, and current collectors.

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Solid electrolyte and method for producing the same with uniform particle size distribution, high crystallinity, and ionic conductivity. The method involves mixing sulfide-based solid electrolyte particles with lithium-metal-oxide and heat treating at 250-350°C. This coats the sulfide particles with lithium oxide on the surface, improving the electrolyte properties by providing a uniform particle size distribution, high crystallinity, and enhanced ionic conductivity compared to just the sulfide electrolyte. The heat treatment range allows crystallization without agglomeration issues.

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Binder solution for all-solid-state batteries with improved electrode performance and higher operating temperatures. The binder solution contains a polymer binder, a first solvent, and an ion-conducting additive. The additive is made by dissolving a lithium salt in a second solvent with higher lithium salt solubility. This creates complex lithium ions that increase the electrostatic attraction of the solution. This higher attraction raises the boiling point of the additive compared to the second solvent. When the binder solution is used in the electrode slurry, the higher boiling point additive prevents evaporation during drying. It also forms a smooth ion transmission path in the electrode. The additive composition allows manufacturing all-solid-state batteries that can operate at temperatures of 70°C or higher.

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An all-solid-state battery system that maintains consistent pressure on the cells during charging and discharging. The system uses a sealed chamber with pressurizing fluid to surround the stack of solid-state cells. A control unit monitors the battery state and sends signals to adjust the pressurizing fluid level to compensate for cell volume changes during charging/discharging. This allows constant, uniform pressure on the cells regardless of charge/discharge state.

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A foldable all-solid-state battery design that avoids short circuits when stacking multiple cells. The battery has folded zigzag layers of anode and cathode electrodes interleaved with electrolyte layers. The folded shape allows the anode protrusions to insert into the cathode recesses and vice versa, preventing short circuits when the cells are stacked. The folded structure is also more compact and enables mass production compared to stacking flat cells.

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All-solid-state battery design with an intermediate layer containing a metal that can form an alloy with lithium to improve energy density. The battery has a negative electrode current collector, an intermediate layer with a metal that forms an alloy with lithium, a solid electrolyte layer, a positive electrode active material layer with the positive electrode active material, and a positive electrode current collector. This intermediate layer composition allows higher lithium metal loading on the anode for improved energy density compared to just using lithium metal on the anode. The metal in the intermediate layer allows better bonding and interfacial stability with the solid electrolyte and lithium metal compared to directly using lithium metal in the anode layer.

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Room temperature all-solid-state battery that can operate normally at room temperature. The battery has a three-layer structure with a negative electrode, an intermediate layer, a solid electrolyte layer, and a positive electrode. The intermediate layer contains carbon and lithium alloy. This allows smooth lithium ion transport at room temperature. The carbon prevents lithium plating on the negative electrode. The lithium alloy forms during charging and provides a seed for lithium deposition. This enables uniform lithium ion precipitation on the negative electrode even at room temperature.

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Anode-free all-solid-state battery design that eliminates the need for a separate anode and uses an intermediate layer containing a metal that can alloy with lithium between the current collectors and solid electrolyte. This allows direct deposition of lithium metal onto the anode collector during discharge instead of using a separate anode. The intermediate layer metal acts as a buffer to prevent dendrite growth and improve cycle life. The amount of metal in the intermediate layer can be optimized based on the cathode capacity to balance performance and capacity.

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All-solid-state battery that can operate at room temperature and method for manufacturing it. The battery has a unique intermediate layer between the negative electrode and solid electrolyte. This layer contains a lithium alloy formed from the negative electrode metal during charging. This allows uniform lithium deposition and prevents dendrite growth. The lithium alloy layer enables stable cycling at room temperature without lithiation reactions at high temperatures. The method involves using a precursor layer with a metal that forms an alloy with lithium, which reacts during charging to form the lithium alloy intermediate layer.

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Cathode material for all-solid-state batteries that improves electron conductivity and enables higher charge/discharge rates. The cathode contains an additive made by calcining a lanthanum, titanium, and lithium precursor. The additive has a unique crystal structure with vacant sites that allows lithium ion migration but prevents electron conduction. This prevents the additive from interfering with the cathode active material's charge/discharge reactions. The additive provides an electron pathway for the cathode during initial cycling when lithium ions are scarce.

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Cathode for all-solid-state batteries that completely coats the cathode active material with a solid electrolyte layer to improve electrochemical performance. The coating layer is formed by applying shear stress to a solid electrolyte powder on the cathode surface. This uniformly covers the active material and provides a seamless interface between the cathode and electrolyte. The coated cathode is mixed with a second solid electrolyte to make the battery electrode.

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Cathode active material and manufacturing method for all-solid-state lithium-ion batteries that improves battery performance and safety. The cathode active material contains a coated core made of a lithium transition metal oxide, with a coating layer consisting of xLi3BO3·(1-x)Li2CO3 (0 <= x <= 1). This composition reduces interface resistance and improves stability compared to traditional cathode materials. The coating is formed by reacting the core with a coating solution during manufacturing.

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A sulfide solid electrolyte material with high lithium ion conductivity for all-solid-state lithium ion batteries. The electrolyte contains silicon as a resource-rich component, providing high ionic conductivity. The material is synthesized by mechanically milling an amorphous precursor and then heating it. The resulting sulfide electrolyte can be used in batteries with layers containing the electrolyte for high-performance all-solid-state lithium ion batteries.

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Cathode design and manufacturing method for all-solid-state batteries that reduces electrolyte degradation during charge/discharge. The cathode has a conductive layer with a carbon-based material and a metal fluoride coating on the surface. This separates the solid electrolyte from the conductive layer, preventing electrochemical decomposition of the electrolyte. The coating minimizes direct contact between the conductive layer and the electrolyte. The cathode active material and electrolyte are also included. The method involves making the coated conductive layer separately and then forming the full cathode.

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Method for manufacturing an electrode for an all-solid-state battery while securing the chemical stability of the sulfide-based solid electrolyte and maintaining the ionic conductivity of the sulfide-based solid electrolyte. The method involves providing a sulfide-based solid electrolyte, coating a non-metal oxide on its surface at 300-700°C, mixing the coated electrolyte with other electrode materials in a polar solvent, casting the slurry onto the electrode current collector, removing the polar solvent, then heating the electrode to 300-700°C to remove the coating. This allows using a highly dispersible polar solvent for slurry preparation without reacting with the sulfide electrolyte, improving dispersibility. The coating prevents reactions between the electrolyte and slurry

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A method for screening solid electrolytes with high lithium ion conductivity and stability for use in solid-state batteries. The screening involves extracting crystal data from a database, selecting compounds with certain site occupancy conditions, substituting elements, and further selecting compounds meeting specific conditions. This iterative process aims to identify solid electrolytes with specific compositions that have high lithium ion conductivity and stability.

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A lithium metal halide-based solid electrolyte for all-solid-state batteries with excellent lithium ion conductivity. The electrolyte has a crystal structure belonging to the C2/m space group. This structure provides high lithium ion conductivity without the issues of anti-site defects seen in other lithium metal halide electrolytes. The specific compositions recommended for the C2/m structure are Li3YCl6, Li2ZrCl6, and Li3AlCl6.

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Method for manufacturing thick electrodes for all-solid-state batteries that enables uniformly manufacturing high loading electrodes for all-solid-state batteries. The method involves preparing a slurry with a wet binder like PVP and a dry binder like polyacrylate. The wet binder provides initial binding for the electrode material while the dry binder is added and kneaded to form a clay-like consistency. This clay is then rolled to form the electrode. The dry binder adds mechanical strength and prevents lifting during rolling. The wet binder ensures adhesion and prevents separation.

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Solid electrolyte for all-solid-state batteries with improved safety and cost compared to liquid electrolytes. The solid electrolyte has an argyrodite-type crystal structure derived from elemental powders of sulfur, phosphorus, lithium, and halogen rather than compound powders. The electrolyte is produced by milling and annealing these elemental powder mixtures. This eliminates the high cost and safety issues of compound powders like Li2S.

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Nitrogen-doped all-solid-state sulfide interface electrolyte for batteries that improves electrochemical safety without impeding ionic conductivity. The electrolyte is a sulfide compound with a specific composition and structure. It contains lithium, phosphorus, sulfur, nitrogen, and halogen (like chlorine) ions. The compound has a silver-germanium-sulfide crystal structure. Adding nitrogen improves safety without reducing conductivity compared to conventional sulfide electrolytes. The nitrogen-doped electrolyte can be used in all-solid-state batteries to improve safety and reduce fire risk compared to liquid electrolytes.

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An all-solid-state battery design with an intermediate layer between the negative electrode current collector and the solid electrolyte to enable uniform lithium deposition during charging. The intermediate layer contains a metal and a metal nitride. The metal assists in lithium deposition and the metal nitride facilitates uniformity. The metal nitride has a non-shared electron pair to avoid chemical bonding between the metals in the layer. The intermediate layer prevents localized lithium precipitation between the collector and electrolyte.

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Nitrogen-doped sulfide-based solid electrolyte for all-solid batteries with improved electrochemical stability. The electrolyte composition is a compound represented by Li6+xPS4-(1-x)-yNzCl(1-z) where 0≤x≤0.5, 0≤y≤0.75, and z=0.25 or 0.5. This composition allows substituting some of the Li2S with Li3N to improve stability while maintaining the argyrodite crystal structure. The nitrogen doping stabilizes the electrolyte against electrolyte decomposition during battery cycling. The nitrogen-doped sulfide-based solid electrolyte can be made by mixing Li2S, P2S5, LiX, and Li3N, grinding, and heat treating to obtain the argyrodite structure.

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A sulfide-based solid electrolyte with high lithium ion conductivity and low interfacial resistance for all-solid-state lithium batteries. The sulfide-based solid electrolyte is produced by pulverizing a crystalline solid electrolyte precursor, followed by firing to form the crystalline solid electrolyte. The finely divided pulverized solid electrolyte has improved lithium ion conductivity and reduced interfacial resistance compared to the crystalline solid electrolyte. The finely divided solid electrolyte can be used in all-solid-state lithium batteries with improved performance and safety compared to liquid electrolyte batteries.

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All-solid-state battery with a protective layer containing a metal sulfide that suppresses lithium dendrite formation and improves battery performance. The protective layer is formed between the solid electrolyte and the negative electrode current collector. It contains a metal sulfide that doesn't react with lithium but allows lithium ions to pass through. This prevents lithium dendrites from growing into the electrolyte and shorting the battery. The protective layer also improves battery life, charge/discharge rate, and temperature range.

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All-solid-state battery with a protective layer containing metal sulfide to suppress lithium dendrite growth and improve battery life, charge/discharge rate, etc. The protective layer is interposed between the anode collector and the solid electrolyte. It contains a metal sulfide incapable of alloying with lithium, along with a metal capable of alloying with lithium. This allows uniform lithium deposition on the anode to prevent dendrites. The metal sulfide fills gaps between the anode and electrolyte and conducts lithium ions.

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Solid-state lithium-ion battery with improved energy density and electrode lifetime by preventing volume expansion and electrode damage during charging and discharging. The negative electrode is composed of a first porous part and a second metal foil part. This allows lithium intercalation and deintercalation without volume expansion, preventing electrode cracking and short circuits. The porous part provides a path for lithium ion movement.

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A nitrogen-doped sulfide-based solid electrolyte for all-solid batteries that improves electrochemical stability compared to conventional sulfide electrolytes. The solid electrolyte contains a compound with the composition Li6-xPS5-xNxCly (0≤x≤1, 0≤y≤2) that has an argyrodite-type crystal structure. Adding a controlled amount of Li3N to the sulfide electrolyte precursor improves stability without degrading ionic conductivity compared to directly replacing some of the Li2S. The doped electrolyte can be prepared by grinding and heat treating a mixture of Li2S, P2S5, LiX, and Li3N.

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Estimating the state of health (SOH) of all-solid-state batteries that can accurately predict battery degradation without using state of charge (SoC) or temperature. The method involves detecting hydrogen sulfide generation inside the battery cells and using pre-prepared data to estimate SOH based on the detected hydrogen sulfide amount or rate. This provides more reliable SOH estimation since hydrogen sulfide generation is a direct indicator of battery degradation that does not depend on SoC or temperature.

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An all-solid-state battery with high energy density and a manufacturing method to produce it. The battery has alternating stacked units of first and second electrodes with solid electrolyte layers between them. Insulating members are inserted between the edges of the first electrode layers and the side surfaces of the second units to prevent short circuits. This allows close stacking of the units without overlapping current collectors to reduce volume and weight compared to stacking full cells. The packed stack is then pressed to bond the layers together.

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An all-solid-state battery with reduced risk of short circuiting during manufacturing due to differential elongation of the cathode and anode layers. The battery has equal area cathode and anode layers initially. During pressing, the different elongation properties of the cathode and anode materials cause the areas to become unequal. This prevents edge contact and short circuiting. The different elongation is achieved by using current collectors with different ductility. The method involves stacking equal area cathode and anode layers, inserting an electrolyte, and pressing. The different elongations cause the cathode and anode areas to become unequal after pressing, preventing edge contact during use.

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Manufacturing all-solid-state batteries to prevent short circuits by stacking pre-pressed electrodes and final pressing. The method involves forming smaller negative and positive electrodes with exposed current collectors, covering them with solid electrolyte layers, and pre-pressing. Then, stacking the pre-pressed electrodes with solid electrolyte facing, final pressing at higher pressure. This prevents electrode deformation and contact during final pressing, preventing short circuits. The symmetrical stacking also reduces warping.

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Cathode material for all-solid-state batteries that prevents lithium ion diffusion between the battery electrodes during charging and discharging. The cathode contains a coating layer made of a compound like LiTaO3 on the cathode active material. The coating layer has nanoscale thickness and is formed by a process involving dissolving precursors, mixing with the cathode material, spray drying, and heat treatment. This coating prevents transition metal ion diffusion between the electrode and solid electrolyte that degrades battery performance.

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Manufacturing composite electrodes for all-solid-state batteries that have improved performance compared to traditional electrodes. The composite electrode is made by preparing a precursor solution of solid electrolyte precursor and polar solvent, stirring it, adding active material, heat treating, and then coating the resulting slurry. The coating step synthesizes solid electrolyte on the active material surface while simultaneously forming a coating layer containing the electrolyte. This improves efficiency and performance compared to sequential steps of dissolving, coating, and heat treating separately.

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Simplified method for manufacturing anode-free all-solid-state batteries with uniform coating layers. The method involves preparing a first and second coating member spaced apart, providing a coating slurry containing carbon and lithium-compatible metals to the first member, inserting a current collector between the members, applying voltage to generate an electric field, and coating the slurry on the current collector through the field. This allows uniform coating distribution without solvent volatilization issues.

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A method to manufacture composite electrodes for all-solid-state batteries by synthesizing the solid electrolyte coating on the electrode material during the slurry preparation step. The method involves mixing the solid electrolyte precursor and a polar solvent to prepare the precursor solution, stirring it, adding the active material to make the electrode slurry, and heat treating it to form the coating layer with the solid electrolyte. This allows simultaneous synthesis and coating of the solid electrolyte on the electrode material compared to separate steps.

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All-solid-state battery design and manufacturing method that improves the performance of the battery edges to prevent short circuits. The method involves coating a hybrid current collector made of a porous metal on the edges of the positive and negative electrodes during battery assembly. This porous metal hybrid collector absorbs some of the electrode material during compression, preventing it from fully contacting the adjacent electrode and shorting. The thin slurry coating on the hybrid collector edges further insulates them. By using the hybrid collector with impregnated electrode material on the edges, it increases utilization compared to just bare metal edges.

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Sulfide-based solid electrolyte for lithium batteries with high ionic conductivity over a wide temperature range for improved battery performance and safety compared to liquid electrolytes. The solid electrolyte contains lithium sulfide, phosphorus pentasulfide, nickel sulfide, and lithium halide. Heat treatment crystallizes the sulfide phases into a cubic structure with gaps between atoms that facilitates lithium ion movement. The nickel and halogen elements contribute to stability and ionic conductivity.

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A method to improve the atmospheric stability and solvent stability of sulfide-based solid electrolytes used in all-solid-state batteries. The method involves mixing a sulfide-based compound with a surface modifying additive, like triphenyl phosphine, and evaporating the solvent to form a solid. The eluted sulfide compound and modifier react on the surface to create a surface modification layer. This layer improves the electrolyte's stability to air and polar solvents compared to plain sulfide electrolytes.

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All-solid-state battery with improved energy density and method for manufacturing same. The battery has a positive electrode layer coated with an insulator to suppress side reactions between the conductive material and solid electrolyte. The insulator coating is applied using atomic layer deposition (ALD). This prevents decomposition of the solid electrolyte and performance degradation due to the conductive material's conductivity.

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Solid electrolyte for all-solid-state batteries that can be prepared using elemental powders instead of costly compound precursors. The electrolyte contains sulfur, phosphorus, lithium, and halogen compounds. The powder mixture is amorphized by grinding and then heat treated to form the solid electrolyte with a thiogallate-type crystal structure. The use of elemental powders reduces cost and eliminates issues with sensitive compounds like Li2S. The amorphization step allows obtaining a uniformly amorphized material for mass production.

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A wet process for making sulfide-based solid electrolytes for lithium batteries with improved properties compared to dry milling methods. The process involves preparing a slurry by adding a solvent to a mixture of lithium sulfide, a group 14 or 15 sulfide, and nickel sulfide. The slurry is then ground to amorphize the mixture, followed by drying to remove the solvent. The dried mixture is then heat treated to crystallize and form the solid electrolyte. This wet grinding, drying, and crystallization sequence provides better ionic conductivity and uniformity compared to dry milling.

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Solid electrolyte derived from a single element for all-solid-state batteries that eliminates safety issues of liquid electrolytes. The solid electrolyte is made by milling and heat treating a mixture of elemental powders (Li, S, P) instead of compound powders. This avoids the high cost and handling hazards of starting materials like Li3PS4. The resulting amorphous mixed powder is crystallized to form the solid electrolyte. The single-element derived electrolyte improves safety and allows larger area batteries compared to compound-based electrolytes.

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An all-solid-state battery with reduced porosity between the electrodes to improve performance and safety. The battery has a sulfide-based solid electrolyte layer sandwiched between a negative electrode with a buffer layer and a positive electrode with a buffer layer. This configuration minimizes the electrode porosity that can occur after rolling by maximizing the interface adhesion areas between the electrode buffer layers and the solid electrolyte. The sulfide electrolyte prevents liquid electrolyte leaks and short circuits.

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