Battery Insulating Layer and Air Gap Design
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Solution Overview
Problem
Conventional battery manufacturing faces challenges in precisely controlling the area of positive-electrode and negative-electrode active material layers, leading to low volume energy density and increased costs due to the need for high dimensional accuracy and additional inspection steps.
Innovation Solution
A battery design featuring an electrode layer, a counter-electrode layer, and a solid electrolyte layer with an insulating layer between the collector and the solid electrolyte layer, and an air gap between the collector and the solid electrolyte layer, which relaxes stress from the electrode active material expansion and contraction, reducing the likelihood of delamination and allowing for easier adjustment of the insulating layer area to minimize non-functional regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the area of positive-electrode and negative-electrode active material layers is precisely controlled, then volume energy density is improved, but manufacturing complexity and inspection requirements increase
Solution Approach 1:
An insulating layer is introduced as an intermediary component between the electrode active material layer and the solid electrolyte layer. This insulating layer serves as a reference structure that defines the functional area of the electrode, allowing the active material layer area to be adjusted without requiring precise dimensional control. The insulating layer mediates the relationship between electrode area and solid electrolyte contact, enabling area adjustment while maintaining proper battery function and reducing manufacturing complexity.
2Volume of moving object
If the insulating layer area is adjusted to minimize non-functional regions, then volume energy density is improved, but manufacturing precision requirements increase
Solution Approach 1:
The insulating layer is formed in advance before the electrode active material layer is applied. By establishing the insulating layer first as a predefined structure, the subsequent electrode material can be applied with less stringent precision requirements. The insulating layer pre-defines the functional boundaries, allowing the electrode material area to be adjusted subsequently without compromising the overall battery performance or requiring high manufacturing precision.
3Quantity of substance
If the electrode active material layer area is increased, then energy capacity is improved, but stress from expansion and contraction increases delamination risk
Solution Approach 1:
The insulating layer acts as a mediator between the electrode active material layer and the solid electrolyte layer. When the electrode active material layer expands and contracts during charge-discharge cycles, the insulating layer provides a buffer zone that reduces stress transmission to the solid electrolyte layer interface. This intermediary structure prevents direct stress concentration at the interface, thereby reducing delamination risk while allowing the electrode area to be increased for higher energy capacity.
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 design enhances battery reliability by reducing delamination risks and increasing volume energy density while simplifying the manufacturing process by allowing for more accurate adjustment of active material layer areas without the need for precise dimensional control.
Implementation Method 1
an air gap between the collector and the solid electrolyte layer, which relaxes stress from the electrode active material expansion and contraction
Data Source
AI summary
A battery includes an electrode layer, a counter-electrode layer placed opposite to the electrode layer, and a solid electrolyte layer located between the electrode layer and the counter-electrode layer. The electrode layer includes a collector, an electrode active material layer located between the collector and the solid electrolyte layer, and an insulating layer located between the collector and the solid electrolyte layer and bonded to the collector at ends of the electrode layer. The electrode active material layer has a region that does not overlap the insulating layer in plan view. The battery has an air gap, the air gap being located between the collector and the solid electrolyte layer and being contact with the insulating layer.