All-solid battery asymmetric electrode pressing
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Solution Overview
Problem
All-solid batteries face issues with battery short-circuit faults due to breakage of edge portions during the pressing process, which is exacerbated by the difference in area between the cathode and anode layers, leading to safety concerns and high manufacturing costs.
Innovation Solution
The solution involves creating an all-solid battery where the cathode and anode layers are stacked with different elongation percentages and thicknesses, allowing the anode layer to have a greater area than the cathode layer after pressing, and optionally using an auxiliary elongation member to enhance the anode's elongation, thereby reducing stress on the edge portions and preventing short-circuits without the need for additional insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the anode layer area is made greater than the cathode layer area to receive all lithium ions, then the battery capacity is improved, but strong stress is applied to the anode edge portion during pressing causing breakage and short-circuit
Solution Approach 1:
The patent applies asymmetry by making the anode layer area greater than the cathode layer area, creating an asymmetric stacking structure. This allows the anode to receive all lithium ions moved from the cathode during charging, improving battery capacity while managing stress distribution through the area difference
Solution Approach 2:
The patent uses preliminary action by pre-forming the anode layer with a larger area before the pressing process. This preliminary area difference prepares the structure to accommodate lithium ions effectively while the pressing process subsequently creates differential elongation that reduces stress on the anode edge portion
2Reliability
If insulator is inserted into the electrode edge portion to ensure insulation performance, then short-circuit prevention is improved, but the insulator itself breaks when the battery is subjected to pressure during fabrication
Solution Approach 1:
The patent extracts the insulator material from the edge portion structure by using the natural oxide layer formed on the aluminum current collector surface. This eliminates the need for separate insulator components that would be susceptible to breaking during pressing, while still providing the required insulation function
Solution Approach 2:
The aluminum current collector performs self-service by naturally forming an oxide layer on its surface that provides insulation functionality. This self-formed protective layer eliminates the need for additional insulator materials and their associated durability issues during the pressing process
3Reliability
If pouch with tape is used to attach the electrode edge portion, then short-circuit fault prevention is improved, but spacing between the pouch and edge portion allows short-circuit to occur
Solution Approach 1:
The patent merges the current collector and electrolyte layer functions by ensuring direct contact between them at the edges through the pressing process. This eliminates the need for separate pouch and tape structures, simplifying the design while maintaining effective short-circuit prevention through direct physical contact
4Reliability
If conventional techniques with additional insulation materials are used, then edge portion insulation is improved, but manufacturing complexity and costs increase reducing mass productivity
Solution Approach 1:
The aluminum current collector provides self-service by naturally forming an oxide layer on its surface that serves as the insulator. This eliminates the need for additional insulation materials and their associated manufacturing steps, thereby reducing manufacturing complexity and costs while maintaining effective edge portion insulation for mass production
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the likelihood of battery short-circuit faults, simplifies the manufacturing process, and lowers costs, ensuring mass productivity by allowing for simpler stacking and pressing without additional insulation, thus enhancing the safety and efficiency of the battery production.
Implementation Method 1
an elongation of the cathode layer and an enlongation of the anode layer may be different upon pressing the stacked cathode layer and anode layer
Data Source
AI summary
Disclosed are an all-solid battery and a method of manufacturing the same. The all-solid battery as disclosed herein may include current collectors having the same size for a cathode and an anode, the elongation areas of the cathode and the anode may be controlled due to the ductility of the current collectors during a pressing process. Thus, areas of the anode and the cathode may become different from each other upon the pressing, thus preventing a short-circuit fault from being formed at the edge portion thereof in the pressing process.