Solid-State Battery Insulating Frame for Electrode Gap Filling

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Solution Overview

Problem

The challenge in solid-state secondary batteries is to maintain a stable position of the positive electrode layer relative to the negative electrode layer without gaps, which can cause positional deviation and reduce the battery's lifetime due to vibrations.

Innovation Solution

Incorporating an insulating frame with a low Young's modulus that can be deformed and spread to fill gaps between the positive electrode layer and the frame, using a composite structure with a high Young's modulus to stabilize the frame's position, and employing a gelatinous insulating material to extrude and fill the gaps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulating frame with high shape stability is used, then the battery lifetime is extended, but gaps form between the positive electrode layer and the insulating frame

Engineering Contradiction:

Improvebattery lifetimeVSAvoidgap between positive electrode layer and insulating frame

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The insulating frame's material parameter (Young's modulus) is changed to be low, enabling the frame to be deformable and fill gaps with the positive electrode layer while maintaining shape stability for battery lifetime extension

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The insulating frame is constructed as a composite structure combining a low Young's modulus body (for gap-filling deformation) with a high Young's modulus outer peripheral portion (for shape stability), resolving the contradiction between gap elimination and shape stability

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If an easily deformable insulating frame is used, then gaps are filled with the positive electrode layer, but the frame lacks shape stability

Engineering Contradiction:

Improvegap filling between positive electrode layer and insulating frameVSAvoidinsulating frame shape stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The insulating frame combines a low Young's modulus body (for gap-filling deformation) with a high Young's modulus outer peripheral portion (for shape stability), resolving the contradiction between gap elimination and shape stability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different portions of the insulating frame have different material properties: the main body has low Young's modulus for deformation and gap-filling, while the outer peripheral portion has high Young's modulus for maintaining shape stability

Inventive Principle:

Principle #3Local quality

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 configuration reduces gaps between the positive electrode layer and the insulating frame, enhancing stability and extending the battery's lifetime by maintaining consistent pressure and insulation.

Implementation Method 1

at least a portion of the insulating frame is pressed in a laminating direction of the electrode laminate and is spread toward a side of the positive electrode layer

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS20250279482A1Solid-state secondary battery and method of manufacturing the same

Publication Date: 2025.09.04 HONDA MOTOR CO LTD

AI summary

A solid-state secondary battery according one embodiment of the present invention includes an electrode laminate that includes a positive electrode layer, a negative electrode layer, and a solid electrolyte layer laminated between the positive electrode layer and the negative electrode layer, and an insulating frame placed on side surfaces of the positive electrode layer with a gap between the positive electrode layer and the insulating frame, in which at least a portion of the insulating frame is pressed in a laminating direction of the electrode laminate and is spread toward a side of the positive electrode layer.