All-Solid Battery Laminate Pressing and Resin Sealing
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Solution Overview
Problem
Existing methods for manufacturing all-solid batteries face challenges such as bending, extrusion, cracking, and high interface resistance due to difficulties in applying high pressure during the roll-pressing process, which affects the connection state and energy density of the battery units.
Innovation Solution
A method involving the use of a mold to press-fit a laminate composed of an anode, solid electrolyte, and cathode cells, along with current collecting plates, at ultra-high pressures, followed by resin injection and solidification to form a compact battery unit without a metal case, allowing for uniform pressure application and gradual pressure increase to prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If roll-pressing is used to manufacture the laminate, then the manufacturing process is simple, but the pressing pressure is insufficient (cannot reach 500 MPa) causing high interface resistance
Solution Approach 1:
The patent changes the pressing method from roll-pressing to uniaxial pressing, which enables achieving the required 500 MPa pressing pressure. This parameter change in the pressing process resolves the contradiction by providing sufficient pressure to reduce interface resistance while maintaining manufacturing feasibility through the use of a simple pressing device with upper and lower pressing members.
2Manufacturing precision
If high pressing pressure (500 MPa) is applied to reduce interface resistance, then energy density improves, but the laminate may crack or deform
Solution Approach 1:
The patent applies pressing pressure in multiple stages rather than applying the full 500 MPa pressure at once. The pressing process includes initial pressing at lower pressure followed by progressive increase to the final high pressure, allowing the laminate to adapt gradually and preventing cracking while achieving the required interface contact.
Solution Approach 2:
The patent places a pressing plate between the laminate and the pressing member to distribute the pressing pressure uniformly across the laminate surface. This cushioning approach prevents localized stress concentrations that could cause cracking while ensuring uniform contact and reduced interface resistance.
3Volume of moving object
If cells are stacked in series without a metal case, then the battery unit becomes compact, but the periphery needs resin sealing for protection
Solution Approach 1:
The patent replaces the traditional metal case with resin material for sealing and protecting the battery unit periphery. The resin injection molding process creates an integrated protective enclosure that is lighter and more compact than metal cases while providing sufficient protection. The resin acts as both the sealing material and the protective case structure.
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 method reduces interface resistance, enhances energy density, and enables the production of compact, series-stacked battery units with improved connectivity and reduced risk of cracking, while eliminating the need for a metal case.
Implementation Method 1
pressing the laminate, producing or forming a battery unit by press-fitting resin from a resin injection port to solidify the resin in the pressed state of the laminate
Implementation Method 2
press-fitting resin by pressing the laminate, and to solidify the resin to manufacture the battery unit
Data Source
AI summary
A method for manufacturing an all-solid battery is provided to press a laminate of a cell becoming a battery unit at a high pressure, and resin-sealing the peripheral thereof. The method includes disposing a laminate, which includes a plurality of cells composed of an anode, a solid electrolyte, and a cathode, and a current collecting plate having the plurality of cells stacked thereon in series and disposed on both end portions thereof in the stacking direction, into a mold in an opened state. The mold is then closed and the laminate is pressed. A battery unit is formed by press-fitting resin from a resin injection port to solidify the resin in the pressed state of the laminate.