All-Solid-State Battery Coating Layout to Prevent Sagging Deformation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing all-solid-state battery manufacturing methods suffer from performance degradation due to coating sagging, leading to deformation and reduced energy density.

Innovation Solution

A manufacturing method involving the formation of a conductive first coating layer on a current collector, followed by a second coating layer that easily peels off, allowing for the removal of sagging portions during hot pressing, and the alignment of electrode layers to reduce deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a slurry is coated to form electrode layers and solid electrolyte layers, then the layers can be formed on the current collector, but coating sagging occurs causing deformation and reduced energy density

Engineering Contradiction:

Improveshape accuracy of electrode layersVSAvoidcoating process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

A release coating layer is formed on the current collector before coating the electrode mixture slurry and solid electrolyte slurry. This preliminary coating creates a release interface that prevents sagging deformation during hot pressing while enabling easy removal afterward, thus maintaining shape accuracy without complicating the coating process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The release coating layer acts as an intermediary between the current collector and the electrode/solid electrolyte layers. It provides a temporary support structure during manufacturing that prevents deformation, then is easily removed to leave clean, accurately shaped layers without directly contacting the active materials

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If hot pressing is applied to densify the stacked body, then the layers are compacted, but coating sagging deformation occurs reducing energy density

Engineering Contradiction:

Improvedensity of stacked bodyVSAvoidshape accuracy of layers

Core Design Contradiction:

Quantity of substanceVSShape

Solution Approach 1:

The release coating layer is applied beforehand to the current collector to create a sag-resistant interface. During hot pressing, this pre-formed layer maintains the shape accuracy of the electrode and solid electrolyte layers while still allowing sufficient densification through the controlled release mechanism

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hot pressing process that would normally cause sagging deformation is converted into a beneficial densification process. The release coating layer transforms the harmful sagging effect into a controlled release mechanism that enables both high density and shape accuracy simultaneously

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If the second coating layer is made to peel easily for removal, then the release function is achieved, but the conductive property may be compromised

Engineering Contradiction:

Improveease of layer removalVSAvoidconductive property of coating layer

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The coating structure is designed with different properties in different regions: the first coating layer maintains high conductivity and strong adhesion for reliable electrical connection, while the second coating layer is formulated with easy-peel characteristics for convenient removal, thus achieving both reliability and ease of manufacture in different parts of the same coating system

Inventive Principle:

Principle #3Local quality

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

Reduces performance degradation by eliminating sagging-induced deformation and enhances the workability of electrically connecting the battery, improving energy density and connectivity.

Implementation Method 1

removing the second coating layer from the first current collector together with a portion of the first electrode layer stacked on the second coating layer

Methodology Applied

Scientific EffectPeeling:

Implementation Method 2

hot pressing a current collector-electrode composite obtained through the forming the first coating layer to the forming the second electrode layer

Methodology Applied

Scientific EffectHot pressing:

Data Source

PatentUS20250219152A1All-solid-state battery, manufacturing method of the same, and conductive coating current collector

Publication Date: 2025.07.03 TOYOTA JIDOSHA KK

AI summary

A method of manufacturing an all-solid-state battery includes: a step of forming a conductive first coating layer in a first region; a step of forming a second coating layer adjacent to the first coating layer in a second region, the second coating layer being easier to peel off than the first coating layer; a step of forming a first electrode layer continuously over the surfaces of the first and second coating layers: a step of forming a solid electrolyte layer on the surface of the first electrode layer; a step of forming a second electrode layer on the surface of the solid electrolyte layer; a step of hot pressing the obtained current collector-electrode composite; a step of removing the second coating layer with each layer thereon from the first current collector; and a step of laminating a second current collector on the surface of the second electrode layer.