Composite Electrode Layering to Prevent Curling in Solid-State Cells

The patent applies a porous structure to the insulating resin layer to reduce shrinkage during curing. The porous network allows the resin to maintain volume stability while providing electrical insulation, preventing curling and peeling that would otherwise occur with dense photocurable resin formation.

The patent uses composite materials by combining photocurable resin with porous forming agents or fillers. This composite approach maintains the electrical insulation properties of the resin while the porous structure compensates for shrinkage, preventing structural defects during the curing and pressing processes.

The patent applies beforehand cushioning by creating a compliant interface layer or using flexible binding materials that can absorb pressing pressure. This cushioning effect protects the solid electrolyte layer from cracking while still achieving the desired high density through controlled compression.

The patent employs parameter changes by carefully controlling pressing pressure, temperature, and curing conditions. By optimizing these parameters, the battery achieves high density without exceeding the fracture threshold of the solid electrolyte layer, preventing cracking while maintaining reliability.

The patent merges the solvent removal processes for both layers into a single simultaneous operation. By using a common drying or heating step that removes solvents from both the insulating resin layer and electrode composite layer at the same time, the patent reduces total process time and prevents curling that would occur with sequential processing.

The patent maintains continuity of useful action by performing solvent removal continuously in one step rather than interrupting for separate processing. This continuous action eliminates the time loss between steps and prevents intermediate curing or deformation that would cause curling and reduce productivity.