All-Solid-State Battery Insulation Screening Before Stack Assembly
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Solution Overview
Problem
The existing methods for producing all-solid-state batteries do not effectively reduce the rate of defective products, as insulation inspection is only performed on stack units after stacking, potentially leading to defective batteries due to undetected non-insulative electrode layers and foreign matter-induced short circuits.
Innovation Solution
A method involving the formation of insulating layer-attached stack units, where a dielectric breakdown test is conducted on each insulating layer to determine non-defective units, which are then assembled into an electrode member and case with a restraint member, applying pressure less than the test pressure to prevent short circuits, and used in environments at or below the test temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation inspection is only performed on stack units after stacking, then the inspection process is simple, but defective units with non-insulative electrode layers or foreign matter cannot be detected, leading to high defective product rates
Solution Approach 1:
The patent applies preliminary action by performing insulation inspection on individual electrode layers before the stacking process. This allows defective layers to be identified and removed prior to assembly, preventing contamination of the entire stack unit and enabling early detection of insulation issues without requiring complex post-stack inspection equipment
Solution Approach 2:
The inspection process is segmented into two distinct stages: (1) insulation inspection of individual electrode layers before stacking, and (2) short circuit inspection of completed stack units after stacking. This segmentation allows each inspection type to be optimized independently, using simple voltage application methods for layer inspection while maintaining overall system reliability
2Measurement precision
If dielectric breakdown test is performed on each insulating layer with high test pressure, then detection accuracy of non-insulative units is improved, but the insulating layer thickness may be compressed and affect battery performance
Solution Approach 1:
The patent applies parameter changes by carefully selecting and optimizing the test pressure value to fall within a specific range that provides sufficient dielectric breakdown detection capability while remaining below the threshold that would cause harmful compression of the insulating layer. This allows the same insulating layer to withstand both the test pressure and the operational pressure during battery use
Solution Approach 2:
The test pressure applied during dielectric breakdown inspection is set to be partially excessive compared to normal operational pressure, providing a safety margin for detection, but deliberately kept below the level that would cause permanent deformation. This partial excess ensures reliable defect detection while the upper bound constraint protects the insulating layer integrity
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 significantly reduces the rate of defective products by ensuring non-defective stack units are used, minimizing the likelihood of short circuits during practical use, and maintaining battery performance across varying temperatures.
Implementation Method 1
performing a dielectric breakdown test on the insulating layer included in the insulating layer-attached stack unit, and determining that the insulating layer-attached stack unit is a non-defective product if no dielectric breakdown is present
Implementation Method 2
assembling a restraint member to the outside of the case... applying pressure less than the test pressure to prevent short circuits
Data Source
AI summary
A method of producing an all-solid-state battery includes forming an insulating layer-attached stack unit including an insulating layer and a stack unit that includes a positive electrode layer, a solid electrolyte layer and a negative electrode layer; performing a dielectric breakdown test on the insulating layer included in the insulating layer-attached stack unit, and determining that the insulating layer-attached stack unit is a non-defective product if no dielectric breakdown is present; forming an electrode member having both ends by disposing the two insulating layer-attached stack units at the both ends, the insulating layer-attached stack unit being determined to be a non-defective product; accommodating the electrode member in a case; and assembling a restraint member to the outside of the case to produce an all-solid-state battery.