Thermosetting Resin Edge Filling for All-Solid-State Battery Short Prevention

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Solution Overview

Problem

All-solid-state batteries face challenges in preventing short circuits due to physical contact between electrodes during the manufacturing process, particularly at the edges, which can lead to deformation and increased risk of shorts.

Innovation Solution

A method involving the application of a thermosetting insulating resin to the inner surfaces of exterior members, which fills the spaces between the edges of the electrode assembly during packaging, thereby preventing physical contact and hardening to support the electrodes, thus preventing shorts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the application area of anode active material is made greater than that of cathode active material to prevent lithium precipitation, then lithium precipitation is prevented, but deformation of the electrode assembly occurs and short circuits are generated due to physical contact between electrodes

Engineering Contradiction:

Improveprevention of lithium precipitationVSAvoidshort circuit due to electrode contact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

An insulating resin is applied in advance to the edges of the electrode assembly before the packaging process. This preliminary application ensures that when the electrode assembly is subsequently pressed or deformed during manufacturing, the insulating resin already in place prevents physical contact between cathode and anode edges, thereby preventing short circuits while maintaining the necessary anode area for lithium precipitation prevention

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the electrode assembly is pressed during manufacturing to improve density and performance, then energy density is improved, but physical contact between electrodes at edges occurs causing short circuits

Engineering Contradiction:

Improveenergy densityVSAvoidshort circuit due to electrode contact

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The insulating resin serves as a protective cushion applied beforehand to the electrode edges. During the pressing operation that improves energy density, this pre-applied resin layer absorbs the compressive force and maintains electrical insulation between opposing electrodes, allowing high-density packaging without causing short circuits

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If additional insulating coatings are applied to electrodes to prevent short circuits, then short prevention is improved, but manufacturing complexity and process steps increase

Engineering Contradiction:

Improveshort circuit preventionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating resin application is merged with the existing electrode assembly packaging process. Instead of adding a separate insulating coating step, the resin is applied to electrode edges as part of the standard packaging workflow, eliminating the need for additional manufacturing steps while providing effective short circuit prevention

Inventive Principle:

Principle #5Merging (Combining)

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 effectively prevents short circuits by filling vacant spaces between electrodes and stabilizing the electrode positions, improving manufacturing workability and cell durability while omitting the need for additional insulating coatings.

Implementation Method 1

the insulating resin applied to the inner surface of the at least one exterior member is forced to fill a space between the edges of the electrode assembly

Methodology Applied

Scientific EffectForced flow of insulating resin:

Implementation Method 2

a thermosetting insulating resin applied in advance to a pouch-type electrode case provided with an electrode assembly received therein is forced to fill a space between the edges of the electrode assembly

Methodology Applied

Scientific EffectThermosetting:

Data Source

PatentUS10686168B2Method of manufacturing short-preventive all-solid-state battery

Publication Date: 2020.06.16 HYUNDAI MOTOR CO LTD

AI summary

A method of manufacturing a short-preventive all-solid-state battery in which a thermosetting insulating resin applied in advance to a pouch-type electrode case provided with an electrode assembly received therein is forced to fill a space between the edges of the electrode assembly during packaging of the electrode assembly to fill vacant spaces between electrodes at the edges of the electrode assembly and may thus prevent physical contact and collision between the electrodes and fundamentally prevent generation of a short circuit caused thereby.