Ceramic Battery Container Metallized Layer Corrosion Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ceramic containers for batteries and electric double layer capacitors face issues with corrosion of metallized layers due to electrolytes, leading to degradation in electrical conductivity and potential disconnection, as well as delamination of ceramic base components.
Innovation Solution
A ceramic container design featuring a ceramic base with a metallized layer extending under a ceramic coating layer and a conductive layer covering both, preventing direct contact with the electrolyte and enhancing corrosion resistance with a sintered alumina coating and specific metal layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallized layer is formed on the ceramic base to improve electrical conductivity, then electrical conductivity is improved, but the metallized layer corrodes and elutes into the electrolyte due to contact, causing degradation in performance and reliability
Solution Approach 1:
A ceramic coating layer is introduced as an intermediary between the metallized layer and the electrolyte. This coating layer acts as a protective barrier that prevents direct contact between the metallized layer and the electrolyte, thereby eliminating corrosion and elution while maintaining electrical conductivity through the metallized layer.
Solution Approach 2:
The ceramic container employs a composite structure consisting of a ceramic base with a metallized layer covered by a ceramic coating layer. This composite design combines the electrical conductivity of the metallized layer with the chemical inertness and protective properties of the ceramic coating, solving both conductivity and corrosion resistance requirements simultaneously.
2Reliability
If the metallized layer is extended to improve electrical connection, then electrical conductivity is improved, but the extended portion becomes more susceptible to corrosion and disconnection
Solution Approach 1:
The ceramic coating layer serves as a protective intermediary that extends along with the metallized layer. This coating prevents the extended metallized layer from corroding or disconnecting, allowing the metallized layer to be extended for better electrical connection without increasing susceptibility to harmful factors.
Solution Approach 2:
The invention changes the protective parameter by applying a ceramic coating layer with specific thickness (5-20 μm) and material properties (chemical inertness, low porosity). This parameter change enables the metallized layer to maintain both extended coverage for electrical connection and protection against corrosion and disconnection.
3Object-affected harmful factors
If a ceramic coating layer is applied to protect the metallized layer from corrosion, then corrosion resistance is improved, but the bonding between ceramic base components may deteriorate due to delamination
Solution Approach 1:
The invention optimizes the thickness parameter of the ceramic coating layer to 5-20 μm. This specific thickness range provides sufficient corrosion protection while maintaining adequate bonding strength between the ceramic base components, preventing delamination. The parameter optimization balances protective function with structural integrity.
Solution Approach 2:
The ceramic container uses a composite structure where the ceramic coating layer is integrally formed with the ceramic base through controlled sintering. This composite approach ensures strong bonding between the coating and base components while maintaining corrosion resistance, eliminating the delamination issue that would occur with poorly bonded coatings.
4Ease of manufacture
If the container structure is simplified to reduce manufacturing complexity, then ease of manufacture is improved, but airtightness and sealing performance may deteriorate
Solution Approach 1:
The ceramic base integrates multiple functions into a single composite component: the ceramic matrix provides structural integrity and chemical inertness, while the metallized layer provides electrical conductivity and the ceramic coating layer provides corrosion protection. This integrated composite structure achieves both manufacturing simplicity and reliable airtightness without requiring separate components for each function.
Solution Approach 2:
The ceramic base is designed as a multi-functional component that simultaneously provides structural support, electrical connection (through metallized layer), corrosion protection (through ceramic coating), and sealing (through integrated construction). This universal design achieves both ease of manufacture and reliable airtightness by eliminating the need for multiple separate components and assembly steps.
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 effectively prevents corrosion and elution of metallized layers, maintains electrical conductivity, and enhances the reliability and airtightness of the battery or capacitor, thereby improving performance and longevity.
Implementation Method 1
a ceramic coating layer formed on a periphery of the bottom face along an inner face of the side wall; a metallized layer extending from a portion provided under the side wall to an inside of an inner end of the ceramic coating layer
Implementation Method 2
The ceramic base 1 is formed of sintered alumina
Implementation Method 3
a conductive layer formed on the bottom face in order to cover an extended portion of the metallized layer and the ceramic coating layer
Data Source
AI summary
A ceramic container includes a ceramic base having a hollow or open portion for accommodating a battery element or an electric double layer capacitor element, defined by a bottom portion and a side wall which surrounds a bottom surface of the bottom portion which bottom face faces the hollow or open portion, a ceramic coating layer formed on a periphery of the bottom face along an inner face of the side wall, a first metallized layer extending, on the bottom face, from a portion provided immediately under the side wall to an inside of an inner end of the ceramic coating layer via a portion provided immediately under the ceramic coating layer, and a conductive layer formed on the bottom face in order to cover an extended portion of the first metallized layer and the ceramic coating layer.