All Solid-State Battery Insulating Resin Application
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Solution Overview
Problem
Existing all-solid-state battery technologies face challenges in precisely applying insulating resin to the end parts, leading to risks of short circuits and sliding down due to electrode damage and incomplete insulation, especially with camber and waviness in the battery structure.
Innovation Solution
The battery design includes an extending part with layered current collector and active material layers, where an ultraviolet cure resin is applied and cured across the surface, side face, and surface of the extending part using a resin applicator with transfer rings and UV light, ensuring precise insulation without damaging the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a dispenser is used to apply resin to the cavity portion, then the resin application process is simplified, but the nozzle may come into contact with the electrode and damage it due to camber and waviness in the battery
Solution Approach 1:
A support member is introduced as an intermediary between the dispenser nozzle and the electrode. The support member extends from the end surface of the casing toward the electrode, providing a physical barrier that prevents the nozzle from contacting the electrode while allowing resin to be applied to the cavity portion. This resolves the contradiction by enabling simplified resin application without compromising electrode integrity.
2Reliability
If a spray method is used to apply resin, then the resin can be applied without contact, but it is difficult to precisely apply the resin to the inside of the cavity at the end part of the electrode to suitably insulate the end part
Solution Approach 1:
The support member acts as a mediator that guides and confines the sprayed resin into the cavity portion. By providing a physical structure that defines the cavity boundaries, the support member enables the spray method to achieve precise resin application within the cavity while maintaining the non-contact advantage of spraying.
3Reliability
If a battery case is filled with thermosetting resin after the battery is stored in the case, then the resin can be applied to the end part, but it is difficult to precisely arrange the resin inside the cavity at the end part of the electrode
Solution Approach 1:
The support member is installed in advance before resin application, pre-defining the cavity structure and boundaries. This preliminary action enables subsequent resin application (whether by dispensing or spraying) to precisely fill the cavity, as the support member already establishes the spatial constraints and guidance structure needed for accurate resin placement.
4Adaptability or versatility
If the anode is larger than the cathode in area, then the battery can be designed with extended anode structure, but the end part of the battery becomes vulnerable to damage and short circuits
Solution Approach 1:
An insulating resin layer is applied to form a protective shell around the end part of the battery where the extended anode structure is vulnerable. This thin film coating provides electrical insulation and mechanical protection to the exposed active material and current collector at the battery end, preventing short circuits and damage while allowing the anode to extend beyond the cathode area.
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 solution effectively suppresses short circuits and sliding down at the battery's end part by providing a precise insulating resin layer, avoiding damage and ensuring accurate insulation across the extending part.
Implementation Method 1
an ultraviolet light source (130) that supplies an ultraviolet ray to at least the clearance (110b)... the ultraviolet cure resin, which is transferred, is cured by the ultraviolet ray from the ultraviolet light source
Data Source
AI summary
A solid-state battery includes a third active material layer, a first solid electrolyte layer, a first active material layer, a first current collector layer, a second active material layer, a second solid electrolyte layer and a fourth active material layer in the order mentioned, wherein both the first and second active layers are anode or cathode active material layers. When both the first and second active layers are anode layers, both the third and fourth active layers are cathode layers. When both the first and second active layers are cathode layers, both the third and fourth active layers are anode layers, at least the first current collector layer extends to an outer side than the third and fourth active layers, and an insulating resin layer continuously across a surface of the extending part on one side, a side face and a surface of the extending part on the other side.