Solid-State Battery Intermediate Layer Pressing to Prevent Pinholes
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Solution Overview
Problem
The formation of pinholes in the intermediate layer of solid-state batteries leads to the risk of dendrite formation, which can compromise the battery's integrity and performance.
Innovation Solution
A method involving the use of two intermediate layers with different densities, where the second intermediate layer is densified through higher pressing pressures, and the application of sequential pressing with varying pressures to integrate the layers, including the solid electrolyte layer, to reduce pinhole formation and enhance bondability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the intermediate layer is made thin to satisfy required conditions, then the battery structure is optimized, but pinholes may form in the intermediate layer
Solution Approach 1:
The intermediate layer is divided into two separate layers: a first intermediate layer with lower density and a second intermediate layer with higher density. This segmentation allows each layer to serve different functions - the first layer provides buffer and adhesion, while the second layer provides densification and pinhole prevention, thereby maintaining thin overall thickness without forming pinholes.
Solution Approach 2:
Different regions of the intermediate layer structure are assigned different densities and properties. The first intermediate layer has lower density for flexibility and adhesion, while the second intermediate layer has higher density for pinhole prevention. This local quality differentiation resolves the contradiction between thinness and pinhole-free structure.
2Length of stationary object
If the intermediate layer is made thin, then the battery structure is optimized, but dendrites may form due to pinholes
Solution Approach 1:
By segmenting the intermediate layer into two layers with different densities, the structure prevents pinhole formation while maintaining thinness, thereby indirectly preventing dendrite formation. The second denser layer specifically addresses the reliability issue by eliminating pinholes that would otherwise serve as dendrite nucleation sites.
3Manufacturing precision
If higher pressing pressure is applied to densify the second intermediate layer, then pinhole formation is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The pressing process is segmented into multiple stages with different pressures applied to different layers. The first intermediate layer is pressed at a lower pressure, while the second intermediate layer is pressed at a higher pressure. This segmented approach achieves pinhole-free density in the critical second layer without requiring excessively high pressure throughout the entire structure, thus managing process complexity.
Solution Approach 2:
The pressing pressure parameter is changed and optimized for different layers. By applying higher pressure specifically to the second intermediate layer during its formation, the process achieves the desired density and pinhole-free structure. This parameter differentiation resolves the contradiction between achieving high precision and maintaining process simplicity.
4Manufacturing precision
If multiple intermediate layers are used with different densities, then pinhole formation is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The intermediate layer is segmented into two layers with different densities, where the first layer has lower density and the second layer has higher density. This segmentation enables each layer to be optimized for its specific function while being integrated through a systematic pressing process, resolving the contradiction between precision and process complexity.
Solution Approach 2:
Different pressing pressures are applied to different layers during manufacturing. The first intermediate layer is pressed at a lower pressure, while the second intermediate layer is pressed at a higher pressure to achieve densification. This parameter differentiation allows precise control over each layer's properties while managing the overall manufacturing complexity.
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 effectively reduces the likelihood of pinhole formation and dendrite growth, leading to improved battery capacity and performance by ensuring tight layer integration and reduced resistance.
Implementation Method 1
press-bonding the first intermediate layer-negative electrode layer laminate and the second intermediate layer, thereby obtaining an intermediate layer-negative electrode layer laminate
Implementation Method 2
pressing the second intermediate layer before the press-bonding the first intermediate layer-negative electrode layer laminate and the second intermediate layer, and a pressing pressure in the pressing the second intermediate layer is higher than a pressing pressure in the press-bonding the negative electrode layer and the first intermediate layer and a pressing pressure in the press-bonding the first intermediate layer-negative electrode layer laminate and the second intermediate layer
Implementation Method 3
press-bonding the negative electrode layer and the first intermediate layer, thereby obtaining a first intermediate layer-negative electrode layer laminate
Data Source
AI summary
A method of manufacturing a solid-state battery that includes an electrode laminate in which a negative electrode layer, an intermediate layer, a solid electrolyte layer, and a positive electrode layer are laminated in this order, the intermediate layer including a first intermediate layer and a second intermediate layer, the method includes: a first step of press-bonding the negative electrode layer and the first intermediate layer, thereby obtaining a first intermediate layer-negative electrode layer laminate; a second step of press-bonding the first intermediate layer-negative electrode layer laminate and the second intermediate layer, thereby obtaining an intermediate layer-negative electrode layer laminate; and a third step of disposing and press-bonding a substance that constitutes the solid electrolyte layer onto a lamination surface of the intermediate layer of the intermediate layer-negative electrode layer laminate, thereby obtaining a solid electrolyte layer-intermediate layer-negative electrode layer laminate.