All-Solid-State Battery Interface with Concave Convex Geometry
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Solution Overview
Problem
The existing methods for manufacturing all-solid-state batteries, such as hot-pressing and hot-isostatic pressing, are costly and time-consuming due to high equipment costs and the need for high temperature and pressure, leading to insufficient interfacial binding between layers, which results in increased interface resistance and potential layer separation.
Innovation Solution
A method involving the formation of concavities and convexities on the surface of green sheets using a sheet member that disappears upon heating, allowing for increased interfacial area and anchor effect, thereby enhancing interfacial strength and reducing interface resistance, while also simplifying the manufacturing process and avoiding equipment damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot-pressing or hot-isostatic pressing method is used to manufacture all-solid-state battery, then interfacial binding force is improved, but manufacturing cost and processing time increase significantly
Solution Approach 1:
The invention applies preliminary action by forming concavities and convexities on the green sheet surface before sintering. This pre-structuring of the interface geometry enables mechanical interlocking that occurs automatically during normal pressing, eliminating the need for subsequent high-temperature hot-pressing treatments while achieving strong interfacial binding.
Solution Approach 2:
The invention utilizes curvature by creating concave and convex surfaces at the interface between layers. These curved geometries provide mechanical interlocking capability, where the convex portions of one layer fit into the concave portions of the adjacent layer, significantly enhancing interfacial strength without requiring expensive hot-pressing equipment.
2Ease of manufacture
If conventional pressing method is used, then manufacturing cost is reduced, but interfacial binding force becomes insufficient leading to layer separation
Solution Approach 1:
The invention applies curvature principles by structuring the interface with concave and convex surfaces. This geometric configuration provides mechanical interlocking that dramatically improves interfacial binding force, preventing layer separation even when using simple, low-cost pressing methods without requiring complex hot-pressing equipment.
Solution Approach 2:
The invention applies segmentation by dividing the interface into multiple convex and concave segments rather than using a flat continuous surface. This segmentation creates multiple interlocking points across the interface, distributing and enhancing the overall binding force while maintaining compatibility with simple pressing processes.
3Device complexity
If flat interface is used between layers, then manufacturing process is simple, but interfacial area is small resulting in high interface resistance
Solution Approach 1:
The invention utilizes curvature by replacing flat interfaces with concave and convex surfaces. This increases the actual contact area between layers, improving ion transport pathways and reducing interface resistance. The curved geometry is formed directly during green sheet fabrication, maintaining manufacturing simplicity while enhancing electrical performance.
Solution Approach 2:
The invention applies dimensionality change by transitioning from a two-dimensional flat interface to a three-dimensional corrugated interface with concave and convex features. This adds vertical dimension to the interface geometry, substantially increasing the effective contact area and improving interfacial properties without complicating the manufacturing process.
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 approach results in improved interfacial strength, reduced interface resistance, and increased yield rate, while maintaining a low manufacturing cost, leading to a reliable and high-performance all-solid-state battery.
Implementation Method 1
a sheet member that is made up of material that is caused to disappear when heated
Implementation Method 2
heating the green sheet and the sheet member that are formed in one piece in the step of forming concavities and convexities, where the sheet member is caused to disappear by heating and where the green sheet is sintered
Data Source
AI summary
The present invention provides a method of manufacturing and an apparatus for manufacturing a layered structure comprising a solid electrolyte layer, a positive electrode active material layer, and a negative electrode active material layer, which together constitute an all-solid-state battery. The layered structure has concavities and convexities formed on the surface and is manufactured by the method comprising the steps of: forming a green sheet S111, where the green sheet for a solid electrolyte layer 11 is formed; forming concavities and convexities S112, where the green sheet for a solid electrolyte layer 11 and the sheet member 50 that is made from material that is caused to disappear when heated, and that has concavities and convexities, are formed in one piece, and the concavities and convexities are formed on the surface of the green sheet for a solid electrolyte layer 11; heating S113, where the sheet member 50 is caused to disappear by heating the green sheet for a solid electrolyte layer 11 and the sheet member 50 that are formed in one piece, and where the green sheet for a solid electrolyte layer 11 is sintered.