Solid-State Battery Sealing Layout to Prevent Micro-Shorts
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Solution Overview
Problem
Conventional battery technologies face challenges in enhancing reliability and mountability, particularly due to issues with mechanical strength and the risk of micro-short circuits caused by non-uniform solid electrolyte layer thickness and density, which can lead to delamination and breakage during shocks or expansions.
Innovation Solution
The battery design includes a positive electrode current collector, a positive electrode active material layer covered by a solid electrolyte layer, a negative electrode active material layer in contact with the solid electrolyte, a negative electrode current collector, and a sealing member positioned outside the solid electrolyte layer, which absorbs shocks and prevents direct contact between electrode surfaces, thereby enhancing mechanical strength and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the solid electrolyte layer is made thinner to reduce battery size, then the battery volume decreases, but the mechanical strength decreases and micro-short circuits occur more easily
Solution Approach 1:
The patent uses a composite structure combining solid electrolyte layer with insulating resin to achieve both thin profile and mechanical strength. The insulating resin reinforces the solid electrolyte layer, preventing breakage and micro-short circuits while maintaining reduced battery volume.
Solution Approach 2:
The patent employs a thin film structure where the solid electrolyte layer is coated on the electrode surface, providing ionic conductivity with minimal thickness. The insulating resin forms a flexible protective layer that maintains mechanical integrity without adding significant volume.
2Ease of manufacture
If the solid electrolyte layer is made non-uniform to simplify manufacturing, then the manufacturing complexity decreases, but delamination and micro-short circuits occur during shocks
Solution Approach 1:
The insulating resin acts as an intermediary layer between the solid electrolyte layer and the external environment. It absorbs shocks and mechanical stresses, protecting the solid electrolyte layer from breakage and preventing delamination, thereby maintaining reliability even with simplified manufacturing processes.
Solution Approach 2:
The insulating resin is applied beforehand to cover the solid electrolyte layer, providing preemptive protection against mechanical shocks and stresses. This cushioning layer prevents micro-short circuits and delamination before they can occur during battery operation or assembly.
3Reliability
If the sealing member is positioned inside the solid electrolyte layer to improve encapsulation, then the encapsulation effectiveness increases, but the risk of micro-short circuits increases due to reduced clearance
Solution Approach 1:
The insulating resin serves as an intermediary barrier between the sealing member and the solid electrolyte layer. It maintains effective encapsulation while providing electrical insulation that prevents micro-short circuits, allowing the sealing member to be positioned optimally for both encapsulation and safety.
Solution Approach 2:
The insulating resin is strategically positioned at critical interfaces where sealing is required, providing localized reinforcement and electrical insulation. This allows the sealing member to maintain close contact for effective encapsulation while the insulating resin prevents micro-short circuits at the sealing interfaces.
4Use of energy by moving object
If the electrode active material layer area is increased to improve capacity, then the energy capacity increases, but the mechanical stress on the solid electrolyte layer increases during expansion
Solution Approach 1:
The composite structure of solid electrolyte layer combined with insulating resin provides both the ionic conductivity needed for high capacity electrodes and the mechanical strength to withstand expansion stresses. The insulating resin reinforces the structure, preventing breakage even with large electrode active material layers.
Solution Approach 2:
The insulating resin is applied beforehand to cover the solid electrolyte layer, providing preemptive protection against mechanical stresses from electrode expansion. This cushioning effect allows larger electrode areas for higher capacity while maintaining mechanical integrity during charge-discharge cycles.
Data Source
AI summary
A battery includes a positive electrode current collector, a positive electrode active material layer, a solid electrolyte layer, a negative electrode active material layer, a negative electrode current collector, and a sealing member. In plan view, the negative electrode active material layer is larger than the solid electrolyte layer. In plan view, each of the positive electrode current collector and the negative electrode current collector is larger than the negative electrode active material layer. In plan view, the sealing member is located outside the solid electrolyte layer. In cross-sectional view perpendicular to a laminating direction, the sealing member is disposed in a region sandwiched between a part of the positive electrode current collector and a part of the negative electrode active material layer and a region sandwiched between another part of the positive electrode current collector and a part of the negative electrode current collector.