Solid-State Battery Current Collector Packaging for Higher Area Density
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Solution Overview
Problem
Current solid-state batteries have limitations in achieving improved area energy density, which is crucial for downsizing and enhancing their performance.
Innovation Solution
The design involves a solid-state battery structure where a first current collector layer is wound to form an outer packaging body around a laminated body including active material layers, an electrolyte layer, and a second current collector layer, eliminating the need for additional sealing materials and allowing increased surface areas for active materials, thereby enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional solid-state battery structures are used with separate sealing materials and components, then structural integrity is maintained, but area energy density is limited
Solution Approach 1:
The current collector layer is designed to serve dual functions: as an electrical conductor for current collection and as a structural sealing component that forms the outer packaging body. This merging of functions eliminates the need for separate sealing materials and reduces the number of components, directly improving area energy density while maintaining structural integrity.
Solution Approach 2:
The current collector layer is configured to perform multiple roles simultaneously: electrical current collection, structural support, and sealing function. By making the current collector multi-functional, the patent reduces component count and increases the proportion of active material area, thereby improving area energy density without compromising battery structure.
2Device complexity
If the current collector layer is wound to form an outer packaging body, then the number of components is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The current collector layer is wound in a spiral or concentric pattern around the active material layers, creating a curved three-dimensional structure. This winding configuration naturally guides the overlapping edges to meet at predictable locations, facilitating precise joining while maintaining the compact cylindrical or spiral battery form factor.
Solution Approach 2:
The current collector layer is wound around the laminated body in a nested configuration where each turn of the winding encompasses the previous turns. This nested structure creates overlapping regions that can be precisely joined, reducing component count while establishing clear joining zones that simplify manufacturing precision requirements.
3Quantity of substance
If additional sealing materials are used to enclose the electrolyte, then reliability is improved, but area energy density decreases
Solution Approach 1:
The current collector layer serves itself by forming the outer packaging body through its own winding and overlapping structure, eliminating the need for separate sealing materials. The overlapping edges of the current collector create self-contained sealing regions that enclose the electrolyte and active materials, maintaining reliability while maximizing active material area.
Solution Approach 2:
The sealing function is merged with the current collector layer itself. The overlapping edges of the wound current collector form sealing regions that simultaneously provide structural enclosure and electrical functionality, eliminating dedicated sealing materials and improving area energy density while maintaining sealing reliability.
Data Source
AI summary
A solid-state battery according to this disclosure is a solid-state battery including a first current collector layer, a first active material layer, a separator layer, a second active material layer, a second current collector layer, and an insulating layer that are laminated in this order. The first current collector layer is wound on a laminated body including the first active material layer, the separator layer, the second active material layer, the second current collector layer, and the insulating layer to surround the laminated body. The first current collector layer forms an outer packaging body such that overlapped parts of the first current collector are joined to each other at a position overlapping with a surface of the laminated body in its lamination direction.