Elastic Solid-State Battery Layers for Volume Change Mitigation

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Solution Overview

Problem

Existing solid state batteries face issues with volume changes during charge and discharge cycles, leading to defects such as crack formation and reduced ionic or electric conductance due to high volume expansions, especially in large energy density applications.

Innovation Solution

Incorporating a compressible elastic composite material with compressible pores into functional layers of the battery, such as current collectors and electrodes, to counteract compressive and tensile forces resulting from volume changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dense packed layers are used in battery design, then micro batteries with low active material can work well, but high volume expansions lead to defect formation and decreased conductance in large applications

Engineering Contradiction:

Improvebattery performanceVSAvoidstructural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies porous materials by incorporating a porous layer between functional layers in the battery stack. This porous layer provides compressibility and expandability to accommodate volume changes during charge-discharge cycles, preventing crack formation and maintaining structural integrity while allowing ion transport through the porous structure.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite materials by creating a multi-layer structure consisting of functional layers (electrodes, electrolyte) combined with a porous compressible layer. This composite design integrates the electrochemical functionality with mechanical compliance, enabling the battery to handle volume expansions without damage while maintaining electrical and ionic conductance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If external pressure is applied to keep stack under continuous pressure, then loss of electric contact is reduced, but volume expansion still causes damage and plastic deformations occur

Engineering Contradiction:

Improveelectric contactVSAvoidstructural damage

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent implements beforehand cushioning by placing a porous compressible layer in advance between functional layers. This layer acts as a cushion that absorbs and accommodates volume expansions before they can cause damage to other components, preventing crack formation and plastic deformations while maintaining continuous electric contact.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent applies flexible structures by using a porous compressible layer that can deform elastically in response to volume changes. This flexible layer maintains contact between functional layers during expansion and contraction cycles without transmitting damaging stresses, unlike rigid external pressure mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The compressible elastic composite material effectively mitigates volume changes, preventing damage and maintaining conductance, thus enhancing the battery's durability and energy density.

Implementation Method 1

a compressible elastic composite material to form one or more of: a compressible and elastic first current collector; and a compressible and elastic positive electrode; and a compressible and elastic solid state electrolyte; and a compressible and elastic negative electrode

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12537202B2Battery cells comprising elastic compressible functional layers and manufacturing process

Publication Date: 2026.01.27 NEDERLANDSE ORG VOOR TOEGEPAST NATUURWETENSCHAPPELIJK ONDERZOEK TNO

AI summary

The present disclosure concerns a rechargeable battery cell comprising a compressible elastic composite material to form one or more of: a compressible and elastic first current collector; and a compressible and elastic positive electrode; and a compressible and elastic solid state electrolyte; and a compressible and elastic negative electrode; and a compressible and elastic second current collector, wherein the compressible elastic composite material comprises a plurality of compressible pores.