Solid-State Battery Electrode Coating via Porous Substrate Filling
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Solution Overview
Problem
Existing methods for manufacturing solid-state batteries face issues with insufficient bonding between electrode layers and the solid-electrolyte layer, leading to increased interface resistance and deterioration of battery characteristics, and are complex and prone to shorting.
Innovation Solution
A method involving an electrode material filling step where a porous conductive base material is filled with an active material slurry to form an electrode body, followed by a solid electrolyte material coating step where at least one electrode body is coated with a solid-electrolyte slurry, and a lamination step to create a solid-state battery, simplifying the manufacturing process and preventing shorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a solid-electrolyte layer is laminated separately onto the electrode material sheet, then the electrode structure is formed, but interface bonding is insufficient leading to increased interface resistance
Solution Approach 1:
The patent combines the electrode material layer and solid electrolyte layer into a single integrated layer where both electrode material and solid electrolyte coexist. This merging eliminates the separate lamination step that caused insufficient bonding, achieving both good interface bonding and low interface resistance simultaneously.
Solution Approach 2:
The patent segments the layer structure at the micro level by distributing electrode material and solid electrolyte as separate phases within the same layer, rather than having them as separate laminated layers. This segmentation approach allows intimate contact between electrode and electrolyte while maintaining structural integrity.
2Reliability
If a conventional multi-step manufacturing process is used, then the battery structure is formed, but the process is complex and prone to shorting
Solution Approach 1:
The patent merges multiple manufacturing steps into a single coating process. Instead of separately forming electrode layers, electrolyte layers, and then assembling them (which risks shorting), the invention forms an integrated layer containing both electrode material and solid electrolyte in one step, eliminating assembly risks and reducing process complexity.
Solution Approach 2:
The patent performs preliminary mixing of electrode material and solid electrolyte before the coating step. By pre-distributing both materials within the same layer during the coating process, the invention eliminates subsequent assembly steps where shorting could occur, achieving reliable battery structure formation in fewer steps.
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 method allows for the effective prevention of shorting and improved bonding between electrode layers, enhancing the characteristics of the solid-state battery while simplifying the manufacturing process.
Implementation Method 1
an electrode material filling step of filling a plurality of holes of a porous conductive base material with an active material contained in an electrode slurry so as to form a first electrode body, by dipping the porous conductive base material having the plurality of holes into the electrode slurry
Implementation Method 2
a solid electrolyte material coating step of coating a surface with a solid electrolyte material contained in a solid-electrolyte slurry by dipping at least one of the first electrode body or a second electrode body having a polarity different from that of the first electrode body into the solid-electrolyte slurry
Data Source
AI summary
A method for manufacturing a solid-state battery includes: an electrode material filling step of filling a plurality of holes of a porous conductive base material with an active material contained in an electrode slurry so as to form a first electrode body, by dipping the porous conductive base material having the plurality of holes into the electrode slurry; a solid electrolyte material coating step of coating a surface with a solid electrolyte material contained in a solid-electrolyte slurry by dipping at least one of the first electrode body or a second electrode body having a polarity different from that of the first electrode body into the solid-electrolyte slurry; and a solid-state battery laminating step of obtaining a solid-state battery by laminating and pressing the first electrode body and the second electrode body.