Solid-State Battery Intermediate Layers for Electrode Bonding

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Solution Overview

Problem

Existing all-solid-state batteries face issues with insufficient bonding between the current collector and active material layers, leading to localized electrochemical reactions and deteriorated cycling characteristics during charge and discharge.

Innovation Solution

Incorporating intermediate layers between the current collector and active material layers, with a bonding rate greater than 1%, and preferably greater than 30%, to enhance bonding and reduce unbonded sections, thereby promoting uniform electrochemical reactions and improving cycling characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If intermediate layers are added between current collector and active material layers, then bonding strength is improved, but device complexity increases

Engineering Contradiction:

Improvebonding strengthVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

An intermediate layer is introduced between the current collector and the active material layer to improve bonding. This intermediate layer acts as a mediator that enhances adhesion between the two layers, preventing delamination and ensuring efficient electron and ion transport during battery operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The intermediate layer is composed of specific materials (such as metal oxides or conductive polymers) that combine the properties of both the current collector and active material, creating a composite structure that optimizes both mechanical bonding and electrochemical performance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If bonding between current collector and active material is improved through intermediate layers, then cycling characteristics are improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecycling characteristicsVSAvoidlayer alignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The intermediate layer is applied to the current collector before the active material is deposited or attached. This preliminary action ensures that the bonding interface is prepared in advance, allowing for better control of the subsequent manufacturing steps and reducing the need for high-precision alignment during final assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The intermediate layer is designed as a thin film that can conform to the surface of the current collector, providing flexible bonding that accommodates slight variations in manufacturing tolerances without compromising the overall structure or performance of the battery.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS12176479B2All-solid-state battery

Publication Date: 2024.12.24 TDK CORP

AI summary

An all-solid-state battery includes a positive electrode current collector layer; a positive electrode active material layer; a negative electrode current collector layer; a negative electrode active material layer; a solid electrolyte layer disposed between the positive electrode active material layer and the negative electrode active material layer and formed of a solid electrolyte; and at least one of a first intermediate layer formed between the positive electrode current collector layer and the positive electrode active material layer, and a second intermediate layer formed between the negative electrode current collector layer and the negative electrode active material layer.