Solid Battery Electrolyte Layer Thinning via Foil Support
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Solution Overview
Problem
Existing methods for manufacturing solid batteries with solid electrolytes face challenges in forming high-power batteries due to cracking and short circuits caused by the pressing of electrolyte material in powder form, which results in difficulty in thinning the solid electrolyte layer without pinholes.
Innovation Solution
A method involving the preparation of a foil-electrolyte laminated body with a binder, followed by lamination and pressing of electrode materials, and subsequent removal of the foil, while using a frame body to ensure tight adherence and prevent short circuits, allowing for a thinned solid electrolyte layer without pinholes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the solid electrolyte layer is thinned to improve output power, then the battery power increases, but short circuit easily occurs
Solution Approach 1:
A foil is introduced as an intermediary support structure during the formation process. The solid electrolyte layer is formed on this foil, which provides mechanical support allowing the layer to be thinned without causing short circuits. The foil acts as a temporary mediator that is removed after the electrode layers are formed, leaving a thin but reliable solid electrolyte layer that prevents short circuits while enabling high output power.
Solution Approach 2:
The foil is prepared in advance as a support structure before forming the solid electrolyte layer. This preliminary action of providing a supportive substrate enables the subsequent formation of a thin solid electrolyte layer that would otherwise be prone to short circuits, thus allowing high power output to be achieved safely.
2Ease of manufacture
If the solid electrolyte layer is formed by pressing electrolyte material in powder form, then the manufacturing process is simple, but cracking easily occurs in the solid electrolyte layer
Solution Approach 1:
The foil serves as an intermediary that enables the pressing process to form a crack-resistant solid electrolyte layer. By providing a supportive substrate during pressing, the foil prevents the electrolyte material from cracking under pressure, while still allowing the simple pressing manufacturing process to be used.
Solution Approach 2:
The invention changes the physical state and formation parameters of the solid electrolyte layer by forming it on a foil substrate. This parameter change allows the layer to be formed with improved mechanical properties and crack resistance while maintaining the simplicity of the pressing manufacturing process.
3Power
If a thinned solid electrolyte layer is formed without a support structure, then the battery power increases, but pinholes and short circuits occur
Solution Approach 1:
The foil acts as a mediator that enables the formation of a thinned solid electrolyte layer without pinholes. During the pressing process, the foil provides uniform support that prevents the formation of pinholes and defects. After the electrode layers are formed, the foil is removed, leaving a pinhole-free thin solid electrolyte layer that enables high battery power.
Solution Approach 2:
The foil is prepared as a support structure in advance, before the solid electrolyte layer is formed. This preliminary support structure prevents pinhole formation during the pressing process, enabling the creation of a thinned layer with high manufacturing precision that is free from pinholes and short circuits.
Data Source
AI summary
Provided is a method for manufacturing a solid battery by which a high-power solid battery can be manufactured. The present invention is a method for manufacturing a solid battery having a pair of electrode layers, and a solid electrolyte layer disposed between the pair of electrode layers, the method including a preparing step to prepare a foil-electrolyte laminated body having a foil and a solid electrolyte layer which contains a binder and is disposed on at least one face of the foil, an electrode layer forming step to form an electrode layer by laminating an electrode material on a surface of the solid electrolyte layer of the foil-electrolyte laminated body prepared by the preparing step and pressing them, and a foil removing step to remove the foil after the electrode layer forming step.