Battery Adhesion Layer Design for Collector Isolation

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Solution Overview

Problem

Existing battery manufacturing techniques often result in excessive contact between positive and negative electrode collectors, leading to short-circuits and degradation of active material and electrolyte layers, particularly in all-solid-state batteries without separators.

Innovation Solution

A battery design featuring a first and second power generating element with a controlled adhesion layer that prevents contact between positive and negative electrode collectors, using a thin, uniform adhesion layer strategically placed between the elements to maintain mechanical and electrical stability, reducing the risk of short-circuits and degradation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thin adhesion layer is used to prevent contact between collectors, then the risk of short-circuits is reduced, but the adhesion strength between laminated elements may be insufficient

Engineering Contradiction:

Improveshort-circuit preventionVSAvoidadhesion strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The adhesion layer is designed with spatially varying properties: in the active material region, it has low thickness or is absent to prevent collector contact, while in the non-active region, it has sufficient thickness to provide strong adhesion between laminated elements. This local differentiation resolves the contradiction between preventing short-circuits and maintaining adhesion strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The adhesion layer is segmented into different regions with different functions: a first region under the active material that prevents collector contact, and a second region in the non-active area that provides mechanical adhesion. This segmentation allows each region to optimize its function without compromising the other.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the positive electrode active material layer is disposed in a region smaller than the positive electrode collector, then the probability of collector contact is reduced, but the energy density may decrease

Engineering Contradiction:

Improvecollector contact preventionVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The solution moves the adhesion function from the active material region to the non-active region, allowing the active material to extend closer to the collector edges without causing short-circuits. This dimensional reorganization preserves both safety and energy density.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The non-active region of the collector acts as an intermediary zone that provides adhesion functionality without interfering with the active material's electrochemical function. This allows the active material to maximize its area while the intermediary region handles the mechanical bonding.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If adhesion portions are formed only at contact points between laminated elements, then the manufacturing process is simplified, but the mechanical stability under high current conditions is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmechanical stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The adhesion layer serves multiple functions simultaneously: it provides mechanical adhesion between laminated elements, prevents collector contact, and maintains structural integrity under high current conditions. This multi-functionality is achieved by extending the adhesion layer into the non-active region where it can perform all these roles without conflict.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The solution effectively reduces the probability of contact between positive and negative electrode collectors, stabilizes electrical conduction, and prevents degradation of active material and electrolyte layers, even under high current conditions and long-term use.

Implementation Method 1

a first adhesion layer adhering the first power generating element to the second power generating element

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11024867B2Battery including adhesion layer adhering positive electrode collector of first power generating element to negative electrode collector of second power generating element, battery manufacturing method, and battery manufacturing apparatus

Publication Date: 2021.06.01 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A battery is provided which includes a first power generating element, a second power generating element, and a first adhesion layer adhering the first power generating element to the second power generating element. A first positive electrode collector of the first power generating element and a second negative electrode collector of the second power generating element face each other with (i.e., via) the first adhesion layer. Between the first positive electrode collector and the second negative electrode collector, the first adhesion layer is disposed in a region forming a first positive electrode active material layer or a region forming a second negative electrode active material layer, whichever is smaller. The first positive electrode collector and the second negative electrode collector are not in contact with each other in a region in which the first positive electrode active material layer and the second negative electrode active material layer face each other.