All-solid lithium battery array with stress-relief connection layers
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Solution Overview
Problem
Existing all-solid lithium batteries face reliability issues due to cracking of film layers, leading to potential short circuits and failure in operation, especially as they become thinner and longer-lasting, necessitating a solution to enhance their structural integrity and operational reliability.
Innovation Solution
The method involves forming lithium battery cells in an array on a substrate with a positive electrode current collector layer, electrolyte layer, and negative electrode current collector layer, along with connection layers to reduce surface stress and prevent cracking, while ensuring proper connection to electrodes, and optionally including an encapsulation layer for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If film-forming all-solid lithium batteries are made thinner to meet demand for lighter and thinner batteries, then weight and thickness are reduced, but the film layers become more prone to cracking which reduces reliability
Solution Approach 1:
The patent divides the battery structure into multiple discrete cells arranged in an array on the substrate. Each cell is separated by isolation layers, creating independent units that can accommodate stress independently. This segmentation prevents cracks from propagating across the entire battery structure, thereby maintaining reliability even as individual cells are made thinner.
Solution Approach 2:
The patent introduces connection layers and isolation layers at specific locations between cells to locally manage stress distribution. These layers are strategically positioned to release surface stress at critical interfaces, preventing crack formation in the thin film layers while maintaining the overall thin profile of the battery.
2Adaptability or versatility
If multiple film layers are stacked to create all-solid lithium batteries, then functional requirements are met, but surface stress accumulates causing cracks in the films
Solution Approach 1:
The patent introduces connection layers and isolation layers as intermediary elements between the stacked film layers. These intermediary layers act as stress buffers that absorb and distribute surface stress, preventing it from accumulating to crack-inducing levels. The connection layers provide mechanical coupling while the isolation layers provide stress decoupling, together protecting the film layer integrity.
3Reliability
If array configuration of M rows×N columns is used instead of single film structure, then reliability is improved by reducing surface stress, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple battery cells into a single integrated array structure on one substrate. The connection layers combine multiple cells electrically and mechanically, while the isolation layers simultaneously separate and protect individual cells. This merging approach achieves the reliability benefits of multiple cells without the proportional increase in manufacturing complexity, as all layers are formed in an integrated process.
Data Source
AI summary
A method for manufacturing an all-solid lithium battery includes: providing a substrate; and forming M rows×N columns of lithium battery cells on the substrate, wherein each of the lithium battery cells includes a positive electrode current collector layer, a positive electrode layer, an electrolyte layer, a negative electrode layer, and a negative electrode current collector layer.