Solid Electrolyte Layer Thickness Variation for Battery Short Circuit Prevention

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Solution Overview

Problem

Existing battery technologies face challenges in preventing short circuits between positive and negative electrode layers due to direct contact, which can lead to instability and increased production complexity, often requiring additional insulation spacers and complex manufacturing steps.

Innovation Solution

A battery design featuring a solid electrolyte layer with varying thicknesses, including a second thickness portion that extends beyond the active material layers to maintain a safe distance between collectors, reducing the risk of contact and eliminating the need for additional insulation spacers, while also allowing for stress relaxation through a space portion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a solid electrolyte layer is formed with uniform thickness covering only the active material layers, then manufacturing is simpler, but the risk of short circuit between collectors increases due to direct contact

Engineering Contradiction:

Improverisk of short circuitVSAvoidsolid electrolyte layer configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The solid electrolyte layer is segmented into two distinct thickness portions: a first thickness portion (first thickness) covering the active material layers, and a second thickness portion (second thickness greater than first thickness) extending beyond the active material layers to the collectors. This segmentation provides electrical insulation between collectors while maintaining manufacturing feasibility through controlled thickness variation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the solid electrolyte layer are given different thicknesses to serve different functions: the first thickness portion provides ionic conduction interface with active materials, while the second thickness portion provides electrical insulation between collectors. This local quality differentiation resolves the contradiction by making the electrolyte layer thickness adaptive to local functional requirements.

Inventive Principle:

Principle #3Local quality

2Reliability

If additional insulation spacers are added to prevent collector contact, then short circuit risk is reduced, but manufacturing complexity and production costs increase

Engineering Contradiction:

Improveshort circuit preventionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulation function previously requiring separate spacer components is merged into the solid electrolyte layer itself. By extending the electrolyte layer's second thickness portion to contact the collectors, the layer simultaneously provides ionic conduction, mechanical support, and electrical insulation functions, eliminating the need for additional insulation spacers and simplifying manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The solid electrolyte layer is designed to perform multiple functions: it serves as the ionic conduction medium (first thickness portion), provides structural support, and acts as the electrical insulator between collectors (second thickness portion). This multi-functionality eliminates the need for separate insulation components and reduces manufacturing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the solid electrolyte layer extends beyond active material layers to contact collectors, then insulation is improved, but stress during expansion may increase

Engineering Contradiction:

Improveelectrical insulationVSAvoidstress resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The solid electrolyte layer is segmented into a first thickness portion that interfaces with active materials and a second thickness portion that contacts collectors. This segmentation allows the thinner first portion to accommodate volume changes of active materials while the thicker second portion provides stable insulation, resolving the stress issue.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrolyte layer has different thicknesses in different regions: the first thickness portion allows for local expansion/contraction of active materials, while the second thickness portion maintains constant dimensional stability for insulation. This local quality variation resolves the contradiction between insulation and stress resistance.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11728516B2Battery, battery manufacturing method, and battery manufacturing apparatus

Publication Date: 2023.08.15 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A battery including a first electrode layer, a solid electrolyte layer on the first electrode layer, a second electrode layer which is located on the solid electrolyte layer and which is a counter electrode layer of the first electrode layer, and a space portion, wherein a first thickness portion is located on the first active material layer, the second thickness portion is located on the first electrode layer, the second active material layer is located at a position which faces the first thickness portion and which does not face the first active material layer via the second thickness portion, the second collector extends to the position facing the second thickness portion and a region provided with the second active material layer, the second thickness portion is in contact with the second electrode layer, and the space portion is surrounded by the second electrode layer and the second thickness portion.