Electrostatic Dry Powder Lamination for All-Solid Secondary Batteries
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Solution Overview
Problem
The existing methods for manufacturing all-solid secondary batteries, such as those described in JP 2012 252833 A, suffer from issues like impurities from solvent-based wet processes remaining in the powder laminate, which can deteriorate battery performance.
Innovation Solution
The proposed installation and method for manufacturing all-solid secondary batteries use a dry process to form a powder laminate with a positive layer, a solid-electrolyte layer, and a negative layer, employing electrostatic film-forming machines and conveyors to ensure uniform mixing and deposition of powder materials without solvent impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wet process is used with slurry prepared by dissolving powder material in solvent, then the powder laminate can be formed, but impurities such as solvent remain in the powder laminate which deteriorate battery performance
Solution Approach 1:
The invention changes the fundamental parameter of the manufacturing process from wet process to dry process. Instead of using slurry with solvent, the invention uses dry powder materials that are directly deposited and sintered. This parameter change eliminates solvent impurities entirely, resolving the contradiction between ease of manufacture and battery performance.
Solution Approach 2:
The invention replaces the chemical-based wet process (slurry deposition) with a physical-based dry process (electrostatic deposition). The electrostatic film-forming device uses electrostatic forces to deposit dry powder materials directly onto the substrate, eliminating the need for solvent and subsequent drying steps, thus avoiding impurity contamination.
2Reliability
If impurities are removed from powder laminate, then battery performance improves, but cavities may be left in the powder laminate
Solution Approach 1:
The invention performs preliminary action by completely avoiding impurity introduction in the first place through dry process manufacturing. Since no solvent is used, there are no impurities to remove, and thus no cavities are created during impurity removal. The sintering process is performed at temperatures and conditions that ensure complete densification without cavity formation.
3Reliability
If electrostatic film-forming device is used to deposit powder material, then uniform powder laminate can be formed without solvent, but complex equipment is required
Solution Approach 1:
The invention introduces an electrostatic field as an intermediary mechanism to achieve uniform powder deposition. The electrostatic film-forming device uses electrostatic forces to control powder particle distribution, ensuring uniform thickness and coverage without requiring complex mechanical manipulation or solvent-based processes. The electrostatic field acts as a mediator that simplifies the deposition control.
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 approach eliminates the presence of solvent impurities and cavities in the powder laminate, thereby enhancing the performance and reliability of the all-solid secondary batteries produced.
Implementation Method 1
an electrostatic film-forming device which forms a powder film from the powder material
Data Source
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AI summary
Provided is an installation (100) for manufacturing an all-solid secondary battery provided with a powder laminate (3) including stacked powder films. The manufacturing installation (100) includes a mixer (10) for mixing multiple kinds of powder materials (A, S) and a conveying device (20) for conveying a powder material (AS) mixed by the mixer (10). The manufacturing installation (100) also includes an electrostatic film-forming device (30) for forming the powder films from the powder material (AS) conveyed by the conveying device (20), by using at least an electrostatic force. In the manufacturing installation (100), a process of forming the powder laminate (3) from the multiple kinds of powder materials (A, S) is a dry process.