Solid-State Battery Layer Sealing for Thin High-Density Cells
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing layer-built batteries, particularly thin layer-built batteries, require improvements to enhance structural stability and energy density while simplifying the manufacturing process and allowing for flexible material selection.
Innovation Solution
A solid-state battery design featuring extended current collector layers joined by a thermoplastic resin layer, with the solid electrolyte and active material layers also connected via the resin, allowing for reduced thickness and increased energy density, and a manufacturing method involving a thermoplastic resin annular sealing member that flows and forms a layer upon heating, sealing the battery layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional layer-building methods are used to manufacture thin solid-state batteries, then manufacturing complexity increases and structural stability deteriorates, but thickness reduction and energy density improvement are desired
Solution Approach 1:
The patent merges the functions of multiple separate layers (current collector, active material, solid electrolyte) into an integrated structure where extended portions of these layers are joined together via thermoplastic resin to form a unified, stable configuration that simplifies manufacturing while maintaining structural integrity
Solution Approach 2:
The patent employs composite material structures by combining different functional layers (conductive current collectors, active materials, solid electrolytes) with thermoplastic resin joiners to create a multi-material system that achieves both structural stability and manufacturing simplicity
2Quantity of substance
If layer thickness is reduced to increase energy density, then structural stability worsens, but higher energy density is required
Solution Approach 1:
The patent implements a nested structure where extended portions of thinner layers are joined together through thermoplastic resin, creating a nested configuration that maintains structural stability despite reduced individual layer thickness, thereby enabling higher energy density
Solution Approach 2:
The patent applies local quality by providing extended portions of layers only where needed for joining and structural support, while keeping the main battery layers thin for high energy density, achieving both stability and density optimization through localized structural enhancement
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 solution provides high structural stability and increased energy density, simplifies the manufacturing process, and offers flexibility in material selection, enabling the creation of thin, high-performance batteries with improved sealing and joining of layers.
Implementation Method 1
a manufacturing method of a solid-state battery including: heating-pressing an unsealed solid-state battery in a state in which an inner-circumferential-side air pressure in a thermoplastic resin annular sealing member is lower than an outer-circumferential-side air pressure of the thermoplastic resin annular sealing member, thereby causing the thermoplastic resin annular sealing member to flow, and forming the thermoplastic resin layer by causing the thermoplastic resin annular sealing member to flow to at least an inner-circumferential-side space of the thermoplastic resin annular sealing member by heating-pressing the unsealed solid-state battery
Implementation Method 2
heating-pressing an unsealed solid-state battery in a state in which an inner-circumferential-side air pressure in a thermoplastic resin annular sealing member is lower than an outer-circumferential-side air pressure of the thermoplastic resin annular sealing member, thereby causing the thermoplastic resin annular sealing member to flow
Data Source
AI summary
A solid-state battery having a first current collector layer, a first active material layer, a solid electrolyte layer, a second active material layer, and a second current collector layer in order as stated is provided. The first current collector layer and the second current collector layer have extended portions, the first current collector layer and the second current collector layer are joined to each other via a thermoplastic resin layer between the extended portions thereof, and (i) an extended portion of the solid electrolyte layer and the second current collector layer are joined to each other via the thermoplastic resin layer or (ii) an extended portion of the first active material layer and the second current collector layer are joined to each other via the thermoplastic resin layer.