Battery Seal Protrusions for Solid Electrolyte Support

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Solution Overview

Problem

Existing battery designs face challenges in maintaining the mechanical strength of the solid electrolyte layer and preventing short circuits due to external forces and direct contact between electrode and counter electrode current collectors, which can lead to collapse and breakage of the unit cell.

Innovation Solution

Incorporating a seal with protrusions that contact the solid electrolyte layer, maintaining a distance between the electrode and counter electrode current collectors, and using materials with specific properties to enhance mechanical reliability and prevent short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a seal is disposed between the electrode current collector and the counter electrode current collector without protrusions, then the structure is simple, but the solid electrolyte layer cannot be supported against external forces leading to collapse and short circuits

Engineering Contradiction:

Improvemechanical reliabilityVSAvoidseal structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protrusions on the seal act as intermediary support elements between the current collectors and the solid electrolyte layer. These protrusions directly contact and support the solid electrolyte layer, distributing external forces and preventing collapse, while the seal itself maintains the electrical insulation function. This intermediary structure resolves the contradiction by adding localized support features without requiring complete structural redesign.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The seal is segmented with multiple protrusions distributed across its surface rather than being a uniform flat structure. This segmentation allows different regions of the seal to perform different functions: the protrusions provide mechanical support to the solid electrolyte layer, while the base seal provides electrical insulation and sealing. This segmented approach improves reliability without excessive complexity increase.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the electrode current collector and counter electrode current collector are placed in direct contact, then the device complexity is reduced, but short circuits occur due to lack of insulation

Engineering Contradiction:

Improveelectrical insulationVSAvoidcurrent collector arrangement

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The seal serves as an intermediary insulating element between the electrode current collector and the counter electrode current collector. It provides electrical insulation to prevent short circuits while maintaining the compact stacked structure of the battery. The seal's presence is necessary but its design is optimized to minimize complexity through the protrusion feature that combines multiple functions.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The seal is designed to perform multiple functions simultaneously: electrical insulation between current collectors, mechanical support for the solid electrolyte layer through protrusions, and sealing of the battery structure. This multi-functionality reduces the need for separate components, thereby maintaining simplicity while ensuring electrical insulation reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the solid electrolyte layer is left unsupported, then the manufacturing process is simpler, but the solid electrolyte layer collapses under external forces causing unit cell breakage

Engineering Contradiction:

Improvestructural stabilityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The protrusions are pre-formed on the seal before assembly, creating built-in support structures that automatically engage with the solid electrolyte layer during assembly. This preliminary action ensures structural stability is built into the design rather than requiring complex external support mechanisms or post-assembly adjustments, maintaining ease of manufacture while improving reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protrusions act as intermediary support elements that directly contact and support the solid electrolyte layer, distributing mechanical loads and preventing collapse under external forces. This intermediary support structure provides structural stability without requiring complex external frameworks or additional manufacturing steps.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11296378B2Battery

Publication Date: 2022.04.05 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A battery includes: a unit cell including an electrode layer, a counter electrode layer facing the electrode layer, and a solid electrolyte layer disposed between the electrode layer and the counter electrode layer; an electrode current collector in contact with the electrode layer; a counter electrode current collector in contact with the counter electrode layer; and a seal disposed between the electrode current collector and the counter electrode current collector. The unit cell is disposed between the electrode current collector and the counter electrode current collector. The seal includes at least one protrusion protruding toward the solid electrolyte layer, and at least part of the at least one protrusion is in contact with the solid electrolyte layer.