Solid-State Battery Coating for Low-Resistance Layer Interfaces

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Solution Overview

Problem

Interfacial resistance in all solid-state batteries is a challenge due to planar geometry and manufacturing processes like physical vapor deposition or electron beam deposition, which increase manufacturing costs and reduce current density.

Innovation Solution

A coating system with continuous deposition of electrode and electrolyte layers using dispensers and rollers to form a layered structure, followed by press rolling to minimize interlayer movement and enhance contact, thereby reducing interfacial resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If physical vapor deposition or electron beam deposition is used to manufacture solid-state batteries, then manufacturing precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvelayer deposition precisionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex physical vapor deposition or electron beam deposition systems with a simpler mechanical extrusion-based coating system. The extrusion process uses a die to deposit electrode and electrolyte layers directly, eliminating the need for expensive and complex vacuum deposition equipment while achieving sufficient layer precision for solid-state battery assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs disposable or replaceable extrusion dies that can be easily changed between production runs. Instead of investing in expensive, complex deposition equipment, the system uses simple, low-cost extrusion tools that can be quickly swapped to produce different battery configurations, reducing both capital expenditure and manufacturing complexity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Manufacturing precision

If physical vapor deposition or electron beam deposition is used to manufacture solid-state batteries, then manufacturing precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvelayer deposition precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent substitutes expensive physical vapor deposition or electron beam deposition equipment with a simple mechanical extrusion system. The extrusion process uses a die to directly deposit materials in a continuous manner, dramatically reducing equipment costs while maintaining adequate layer precision for battery assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a continuous extrusion process that deposits electrode and electrolyte layers in a single continuous operation rather than through multiple discrete deposition steps. This continuous action reduces manufacturing time and cost while maintaining consistent layer quality throughout the battery assembly.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If planar geometry is used in solid-state batteries, then device simplicity is improved, but interfacial resistance increases

Engineering Contradiction:

Improvebattery structure simplicityVSAvoidinterfacial contact quality

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent introduces curved or non-planar features to the electrode and electrolyte interfaces during the extrusion process. By creating slight curvature or surface variation at the interfaces, the system improves contact area and reduces interfacial resistance while maintaining the overall simplicity of the planar battery structure.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent applies local quality variations at the interfaces between electrode and electrolyte layers through the extrusion process. The die geometry is designed to create locally optimized contact surfaces with enhanced roughness or curvature at critical interfaces, improving interfacial adhesion and reducing resistance without complicating the overall battery structure.

Inventive Principle:

Principle #3Local quality

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 improves interfacial contact and reduces resistance, enabling efficient production of solid-state batteries with enhanced current density and reduced manufacturing complexity.

Implementation Method 1

drums for press rolling the layered structure to form a solid-state battery

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12537216B2Multi-layer all solid-state battery coating

Publication Date: 2026.01.27 FORD GLOBAL TECH LLC

AI summary

A coating system for a solid-state battery includes a feeder for a first substrate foil, and an electrolyte dispenser between two electrode dispensers. The first electrode dispenser has a first mixture of a first solid active material and a first solid electrolyte therein, and deposits a first electrode layer on the foil. The electrolyte dispenser deposits an electrolyte layer on the first electrode layer. The second electrode dispenser has a second mixture of second solid active material and a second solid electrolyte, and deposits a second electrode layer on the electrolyte layer. A roller provides a second substrate foil downstream of the second electrode dispenser on the second electrode layer to form a layered structure. The system also includes drums for press rolling the layered structure to form a solid-state battery, with the layers being continuously deposited.