Laminated All-Solid-State Battery Edge Deformation Control

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Solution Overview

Problem

Existing laminated all-solid-state batteries face issues with edge deformation during vacuum sealing, leading to short-circuiting, and have suboptimal performance due to excessive non-power generating volume when covered with resin or insulating layers.

Innovation Solution

A method involving housing an all-solid-state battery laminate in a laminated film casing, pressing it, injecting a filler with controlled viscosity, and sealing while maintaining pressure to prevent edge deformation and optimize volume usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If all-solid-state battery elements are covered with resin or insulating layers to prevent short-circuiting, then reliability is improved, but the volume of non-power generating constituents increases, reducing battery performance per volume

Engineering Contradiction:

Improveshort-circuit preventionVSAvoidbattery performance per volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The invention extracts the protective function from traditional resin/insulating layers and relocates it to the edge-sealing structure of the laminated film casing itself. The casing edges are designed to directly contact and seal the battery laminate edges, eliminating the need for additional protective layers while maintaining short-circuit prevention.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The laminated film casing serves as both the structural container and the protective element. The thin film structure provides edge sealing and short-circuit prevention without adding significant volume, replacing the need for bulky resin coatings or protruding insulating layers.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If vacuum sealing is applied to seal the laminated film casing, then sealing reliability is improved, but edge deformation of the battery laminate occurs, causing short-circuiting

Engineering Contradiction:

Improvesealing reliabilityVSAvoidedge deformation

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention provides beforehand cushioning by designing the casing structure to include edge contact features that physically support the battery laminate edges during vacuum sealing. This structural cushioning prevents edge deformation before it can occur, allowing vacuum sealing to be applied without causing short-circuiting.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The casing edges act as an intermediary element between the vacuum sealing force and the battery laminate. The intermediary structure distributes the vacuum pressure and provides mechanical support to prevent direct deformation of the laminate edges during the sealing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If the battery laminate is pressed in the lamination direction during filler injection, then filler injection completeness is improved, but edge deformation in the planar direction may occur

Engineering Contradiction:

Improvefiller injection completenessVSAvoidedge deformation in planar direction

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention segments the pressing function into two independent actions: lamination-direction pressing during filler injection, and planar-direction edge support during sealing. This segmentation allows each direction to be optimized independently, ensuring complete filler injection without causing planar edge deformation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The casing structure is designed with preliminary edge support features that are in place before filler injection begins. This preliminary action prevents edge deformation in the planar direction while allowing effective pressing in the lamination direction to ensure complete filler injection.

Inventive Principle:

Principle #10Preliminary action

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 method produces a laminated all-solid-state battery with superior performance per volume, inhibiting edge deformation and preventing short-circuiting, while minimizing non-power generating volume, thus enhancing battery efficiency.

Implementation Method 1

injecting a filler into the casing while maintaining pressure

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

pressing the all-solid-state battery laminate housed in the casing in the direction of lamination from outside the casing

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS10971707B2Laminated all-solid-state battery including a filler

Publication Date: 2021.04.06 TOYOTA JIDOSHA KK

AI summary

A method for producing a laminated all-solid-state battery 100, including: housing an all-solid-state battery laminate 15, having one or more all-solid-state unit cells, in a casing 20 composed of a laminated film 21, the one or more all-solid-state unit cells obtained by laminating a negative electrode current collector layer having a negative electrode current collector tab 1a, a negative electrode active material layer, a solid electrolyte layer, a positive electrode active material layer and a positive electrode current collector layer having a positive electrode current collector tab 5a in this order, pressing the all-solid-state battery laminate 15 housed in the casing 20 in the direction of lamination from outside the casing 20, injecting a filler into the casing 20 while maintaining pressure, and sealing the casing 20.