Solid Electrolyte Sheet Layout for Reliable All-Solid-State Batteries
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Solution Overview
Problem
Existing all-solid-state batteries face challenges in maintaining high productivity due to issues with charging abnormalities, particularly when large numbers are produced, which can lead to decreased reliability and increased costs.
Innovation Solution
The all-solid-state battery design incorporates a solid electrolyte sheet with a porous substrate biased toward the positive electrode, ensuring both surfaces of the porous substrate are covered with solid electrolyte, and maintaining a thickness of 50 μm or less to minimize internal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the porous substrate is positioned centrally in the solid electrolyte sheet, then the structure is symmetric and easier to manufacture, but charging abnormalities occur during mass production
Solution Approach 1:
The patent applies asymmetry by intentionally positioning the porous substrate biased toward the positive electrode side rather than centrally. This asymmetric configuration prevents charging abnormalities during mass production while maintaining manufacturing feasibility. The biasing creates an optimized ion transport pathway that resolves the charging performance issues associated with symmetric central positioning.
Solution Approach 2:
The patent applies local quality by creating different regions within the solid electrolyte sheet with distinct functions. The porous substrate region biased toward the positive electrode provides enhanced local ion conductivity and contact in that specific area, while other regions maintain their standard structure. This localized optimization solves the charging abnormality problem without requiring complete structural redesign.
2Strength
If the solid electrolyte sheet thickness is increased, then mechanical strength is improved, but internal resistance increases and productivity decreases
Solution Approach 1:
The patent utilizes porous materials by incorporating a porous substrate within the solid electrolyte sheet. This porous structure provides high surface area and enhanced ion transport pathways, allowing the sheet to maintain low internal resistance and high charging rates even at reduced thickness. The porosity compensates for the reduced bulk thickness, resolving the contradiction between strength and productivity.
Solution Approach 2:
The patent applies composite materials by combining the porous substrate with the solid electrolyte matrix to create a hybrid structure. This composite configuration provides both mechanical reinforcement from the substrate framework and efficient ion conduction through the porous network, enabling thin sheets to achieve both high strength and high productivity simultaneously.
3Reliability
If both surfaces of the porous substrate are covered with solid electrolyte, then ion transport is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the porous substrate with the appropriate biasing position before final assembly into the solid electrolyte sheet. This preliminary positioning ensures that both surfaces will be properly covered with solid electrolyte during subsequent manufacturing steps, simplifying the overall process while guaranteeing the desired ion transport properties. The pre-biased substrate reduces the complexity of achieving uniform coverage.
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 configuration effectively suppresses charging abnormalities, enhances battery reliability, and increases productivity by ensuring consistent performance across multiple batteries.
Implementation Method 1
a solid electrolyte sheet containing a porous substrate and a solid electrolyte, in which the solid electrolyte is retained in pores of the porous substrate
Data Source
AI summary
Provided is an all-solid-state battery with high productivity. An all-solid-state battery according to the present invention relates to Goals 3, 7, 11, and 12 of SDGs. An all-solid-state battery according to the present invention includes a stacked body provided with a positive electrode, a negative electrode, and a solid electrolyte sheet interposed between the positive electrode and the negative electrode, in which the solid electrolyte sheet contains a porous substrate and a solid electrolyte, the solid electrolyte is retained in pores of the porous substrate, both surfaces of the porous substrate are covered with the solid electrolyte, and in the solid electrolyte sheet, the porous substrate is located biased toward the positive electrode in a thickness direction of the solid electrolyte sheet, and the solid electrolyte sheet has a thickness of 50 μm or less.