Solid-State Battery Foil Lamination With Press-Roller Adhesive Bonding
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Solution Overview
Problem
Conventional all-solid-state battery manufacturing methods are inefficient in adhering multiple layers, leading to prolonged manufacturing times and potential disturbances in battery shape, which can affect performance.
Innovation Solution
An all-solid-state battery manufacturing apparatus and method utilizing a press roller with an adhesive roller to efficiently adhere a current collection foil to an active material layer, with the adhesive roller adjusting the adhesive thickness and a curing light unit for photocurable adhesives, allowing for faster and more precise bonding without heat-induced distortions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers are bonded by heating and compressing using a flat plate, then the layers can be adhered together, but the manufacturing time cannot be shortened
Solution Approach 1:
The patent replaces the conventional flat plate pressing method with a cylindrical press roller. The curved surface of the roller enables continuous rotation and pressing action, allowing the current collection foil to be continuously fed and pressed against the active material layer while the roller rotates. This curvature-based mechanism transforms the batch processing into continuous processing, significantly reducing manufacturing time while maintaining adhesion quality through consistent pressure application.
Solution Approach 2:
The invention introduces dynamic motion to the pressing process. The press roller rotates continuously during the bonding operation, and the adhesive roller simultaneously rotates to apply adhesive to the moving current collection foil. This dynamic approach allows multiple layers to be adhered in a continuous flow rather than static batch processing, reducing the time required for manufacturing while ensuring proper adhesion through controlled rotational speeds and pressure.
2Reliability
If multiple layers are bonded by heating and compressing using a flat plate, then the layers can be adhered together, but the battery shape may be disturbed
Solution Approach 1:
The cylindrical press roller distributes pressing pressure uniformly across the battery layers through its curved surface. As the roller rotates, it applies consistent pressure without creating localized stress concentrations that could distort the battery shape. The adhesive roller similarly applies adhesive uniformly to the current collection foil. This curvature-based approach replaces the potential for shape disturbance from flat plate compression with uniform pressure distribution.
3Manufacturing precision
If adhesive thickness is reduced by extending pressing time with a flat plate, then adhesion quality improves, but manufacturing time increases
Solution Approach 1:
The adhesive roller applies adhesive to the current collection foil before the pressing operation begins. This preliminary adhesive application allows for precise control of adhesive thickness through the roller's rotation speed and positioning, eliminating the need for extended pressing time to achieve proper adhesive distribution. The adhesive is uniformly applied in a controlled manner as the foil moves through the system, ensuring consistent thickness without requiring prolonged compression.
Solution Approach 2:
The invention replaces the mechanical pressing-only method with a combined adhesive application and pressing system. The adhesive roller uses rotational motion to precisely control and apply adhesive at a consistent thickness, substituting the need for time-dependent pressure-based adhesive distribution. This mechanical-substitution approach allows rapid adhesive application with precise thickness control, significantly reducing the time required compared to conventional pressing methods.
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 significantly reduces manufacturing time while maintaining the integrity of the battery shape, ensuring better performance and efficiency in adhering the current collection foil and active material layer.
Implementation Method 1
a viscosity of the adhesive when provided to the current collection foil is 100 mPa·s to 5000 mPa·s
Implementation Method 2
press the current collection foil and the active material layer in a thickness direction between the press roller and the support surface
Implementation Method 3
an adhesive provision apparatus that is provided on a movement path of the current collection foil rotated and moved by the foil attachment surface of the press roller, and that is configured to provide an adhesive to the current collection foil attached to the press roller
Data Source
AI summary
An all-solid-state battery manufacturing apparatus disclosed herein includes a transport apparatus, a press roller, and an adhesive provision apparatus. The transport apparatus transports an active material layer. The press roller has a foil attachment surface, which is a cylindrical surface to which the current collection foil is to be attached. The press roller rotates and moves the current collection foil attached to the foil attachment surface to the surface of the active material layer being transported by the transport apparatus and presses the current collection foil and the active material layer between the press roller and the transport apparatus. The adhesive provision apparatus is provided on a movement path of the current collection foil rotated and moved by the foil attachment surface of the press roller, and provides an adhesive to the current collection foil attached to the press roller.