Battery Electrode Sealing Structure for Low-Profile Stacked Cells
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Solution Overview
Problem
The existing methods for manufacturing stacked all-solid-state batteries result in increased battery thickness due to insulating resin jutting out in the laminating direction, which reduces structural efficiency.
Innovation Solution
An electrode design featuring a laminate with an active material layer and current collector, where the sealing portion is composed of a first and second sealing portion, with the second sealing portion being recessed into asperities on the adjacent face, preventing jutting out and ensuring firm adhesion and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulator coating solution is coated on end portion of laminate to seal it, then insulation is improved, but battery thickness increases due to insulating resin jutting out
Solution Approach 1:
The patent applies local quality by creating asperities (surface irregularities) only at specific locations on the adjacent face where the sealing portion contacts the electrode. This localized surface treatment allows the sealing portion to conform to the asperities and be pressed into recessed portions, preventing jutting out while maintaining insulation. The asperities are formed only in the region where the sealing portion contacts the electrode, not across the entire surface.
Solution Approach 2:
The patent applies preliminary action by forming asperities on the adjacent face before applying the insulator coating solution. This pre-formed surface structure guides the sealing portion material to flow into the asperities during the pressing process, ensuring that the sealing portion conforms to the asperity pattern and does not jut out. The asperities are created in advance to control the final shape and position of the sealing portion.
2Length of stationary object
If sealing portion is pressed into recessed portions of asperities, then battery thickness is reduced, but adhesion and insulation may be compromised
Solution Approach 1:
The patent applies the porous materials principle by utilizing the asperities as micro-cavities or recessed portions that the sealing portion material can penetrate and conform to. The asperities create a textured surface with increased surface area and mechanical interlocking features, allowing the sealing portion to adhere firmly while maintaining insulation. The recessed portions of the asperities act like a porous structure that the sealing material fills, enhancing both adhesion and insulation properties.
Solution Approach 2:
The patent applies composite materials by combining the sealing portion material with the asperity structure to create a composite interface. The sealing portion, when pressed into the asperities, forms a composite structure where the sealing material and the asperity surface work together to provide both mechanical adhesion and electrical insulation. This composite approach ensures that the sealing portion maintains strong adhesion and effective insulation while conforming to the asperity pattern.
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
An electrode (1) for a battery includes a laminate including an active material layer (13a, 13b) and a current collector (11), and a sealing portion covering an end portion surface of the laminate. The laminate includes two principal faces facing each other, and an end face (1a). The end portion surface includes the end face (1a), and an adjacent face (1b) on each of the two principal faces. The adjacent face (1b) includes one or more asperities. The sealing portion includes a first sealing portion (Sa) covering the end face (1a), and a second sealing portion (5b) covering at least part of the adjacent face (1b). The second sealing portion (5b) is present in one or more recessed portions of the one or more asperities of the adjacent face (1b) and does not include a portion higher than a height position (H) of the one or more asperities that is highest. The first sealing portion (5a) and the second sealing portion (5b) are connected.