Bipolar Solid-State Battery Manufacturing via Continuous Current Collector Winding
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Solution Overview
Problem
Current manufacturing methods for solid-state batteries, particularly bipolar solid-state batteries, suffer from low productivity rates, hindering the production of high-performance batteries.
Innovation Solution
A method involving the disposition of cell units along a continuous current collector, followed by winding and application of heat and pressure to form a compressed stack, and subsequent cutting of the current collector to create the solid-state battery, utilizing a z-folded or cladded foil with polymeric coatings for improved adhesion and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manufacturing methods are used for solid-state batteries, then manufacturing simplicity is maintained, but productivity is low
Solution Approach 1:
The battery structure is segmented into discrete cell units (e.g., 220, 222, 224, 226) that can be independently assembled along the continuous current collector. Each cell unit contains specific electrodes and electrolyte layers, allowing modular manufacturing and assembly, which increases productivity while maintaining process manageability
Solution Approach 2:
The current collector (232) is prepared in advance with specific surface treatments, coatings, or structural features before cell units are assembled onto it. This preliminary preparation enables faster assembly operations and improves manufacturing efficiency without significantly complicating the overall process
2Productivity
If cell units are disposed along continuous current collector with winding, then manufacturing productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
An intermediary layer or feature is introduced between the cell units and the current collector to facilitate precise positioning and alignment. This intermediary element acts as a guide or reference that ensures accurate placement of cell units during assembly, maintaining manufacturing precision while enabling continuous production
Solution Approach 2:
Traditional mechanical alignment methods are replaced with alternative approaches such as magnetic positioning, adhesive patterns, or geometric interlocking features integrated into the current collector or cell units. This substitution enables more precise and consistent positioning without complex mechanical adjustment mechanisms
3Strength
If heat and pressure are applied to form compressed stack, then structural integrity is improved, but energy consumption increases
Solution Approach 1:
Cell units are pre-compressed or pre-bonded before final assembly into the stack. This preliminary compression reduces the gap between components and improves contact, so that less energy is required during the final heat and pressure treatment to achieve the desired structural integrity
Solution Approach 2:
The heat and pressure treatment parameters are optimized and adjusted based on the specific stage of manufacturing. By controlling temperature, pressure, and time parameters more precisely, the process achieves adequate structural integrity with reduced energy input compared to conventional high-energy compression 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 method enhances the productivity of solid-state battery manufacturing by forming high-performance batteries with improved structural integrity and conductivity, addressing the low productivity issues of existing methods.
Implementation Method 1
applying heat, pressure, or a combination of heat and pressure to the stack precursor to form a compressed stack
Implementation Method 2
applying heat, pressure, or a combination of heat and pressure to the stack precursor to form a compressed stack
Implementation Method 3
The continuous current collector may be a z-folded current collector and the disposing the one or more cell units along the continuous current collector may include inserting the one or more cell units into one or more pockets formed by folds of the continuous current collector
Implementation Method 4
utilizing a z-folded or cladded foil with polymeric coatings for improved adhesion and conductivity
Data Source
AI summary
A method for forming a solid-state battery is provided. The method includes disposing one or more cell units along a continuous current collector to form a stack precursor. In some examples, disposing of the one or more cell units along the continuous current collector includes concurrently disposing the one or more cell units along the continuous current collector and winding the continuous current collector to form a stack. In other examples, the continuous current collector is a z-folded current collector and the disposing the one or more cell units along the continuous current collector includes inserting the one or more cell units into one or more pockets formed by folds of the continuous current collector. The method may further include applying heat, pressure, or a combination of heat and pressure to the stack precursor to form a compressed stack, and cutting the continuous current collector to form the solid-state battery.