Solid-State Battery Lamination With Pre-Cut Insulator Alignment
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Solution Overview
Problem
Existing manufacturing techniques for all-solid-state batteries lack efficient methods for appropriately bonding electrodes and insulating members, leading to suboptimal manufacturing efficiency and alignment issues during the roll press process.
Innovation Solution
An apparatus comprising a conductor conveyor, an insulator conveyor, a cutter, and a laminator-pressurizer that conveys and cuts insulating members in parallel with electrodes, ensuring appropriate bonding and high manufacturing efficiency by maintaining tension and removing unnecessary portions, thereby facilitating the production of all-solid-state batteries with improved alignment and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a roll press process is employed to manufacture all-solid-state batteries, then manufacturing efficiency is improved, but alignment and bonding between electrodes and insulating members deteriorates
Solution Approach 1:
The insulating member is pre-shaped by the cutter to match the electrode geometry before lamination. This preliminary shaping ensures that when the electrode and insulating member are stacked and pressed, their interfaces align perfectly without requiring complex alignment procedures during the pressing operation, thus maintaining both high productivity and manufacturing precision
Solution Approach 2:
The insulating member acts as an intermediary element that is precisely shaped to fit between electrode components. By pre-forming the insulating member with the exact geometry needed, it serves as a positioning intermediary that facilitates automatic alignment during stacking, eliminating the need for complex alignment mechanisms while maintaining bonding quality
2Manufacturing precision
If insulating members are disposed on electrode layers to facilitate alignment, then alignment is improved, but device complexity increases
Solution Approach 1:
The insulating member is designed to be self-aligning through its geometric shape that matches the electrode. The cutter shapes the insulating member to have features that naturally guide its position relative to the electrode during stacking. This self-service alignment mechanism eliminates the need for complex external alignment devices, fixtures, or positioning mechanisms, thus improving alignment without significantly increasing device complexity
Solution Approach 2:
The insulating member has locally optimized geometry with specific features at critical positions that enable automatic alignment. Rather than making the entire insulating member complex, only specific local regions are shaped to provide alignment functionality, keeping the overall device complexity low while achieving precise alignment
3Productivity
If the insulator is conveyed and cut in parallel with the conductor, then manufacturing efficiency is dramatically improved, but bonding precision may deteriorate
Solution Approach 1:
The insulating member is pre-cut into its final shape while being conveyed in parallel with the electrode. This preliminary cutting action ensures that the insulating member is ready for immediate lamination without requiring additional processing steps. The pre-shaping maintains geometric precision while the parallel conveyance maintains high manufacturing efficiency
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a conveyor-based synchronized transport system. By using conveyors to move both the electrode and insulating member in parallel at controlled speeds, the system maintains precise relative positioning through synchronization rather than mechanical alignment fixtures, thus maintaining bonding precision while achieving high manufacturing efficiency
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 apparatus effectively manufactures all-solid-state batteries with high efficiency by ensuring proper bonding and alignment of electrodes and insulating members, enhancing the overall manufacturing process and resulting product quality.
Implementation Method 1
a laminator-pressurizer configured to laminate and pressurize the conductor conveyed by the conductor conveyor and the insulator having the cut formed by the cutter
Data Source
AI summary
Provided is an apparatus for manufacturing an all-solid-state battery with high efficiency. An apparatus for manufacturing an all-solid-state battery includes: a conductor conveyor configured to convey a conductor adapted to function as an electrode that is an element of the all-solid-state battery; an insulator conveyor configured to convey an insulator adapted to function as an insulating member that is an element of the all-solid-state battery; a cutter configured to form, in the insulator, a cut in correspondence with the shape of the insulating member; and a laminator-pressurizer configured to laminate and pressurize the conductor conveyed by the conductor conveyor and the insulator having the cut formed by the cutter.