Solid-State Battery Subdivided Electrodes Defect Isolation
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Solution Overview
Problem
Solid-state battery structures and manufacturing methods require optimization to reduce fabrication costs and improve performance, particularly due to defects in the electrolyte layer causing internal short-circuiting and degradation of battery performance.
Innovation Solution
The implementation of subdivided electrode layers with gaps between subregions, where the cathode and anode layers are electrically connected through continuous current collectors, and the gaps are partially filled with dielectric materials, effectively isolating subregions and reducing the impact of defects in the electrolyte layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrolyte layer is made continuous to ensure ion transport, then ion conductivity is improved, but defect formation (cracks and pinholes) increases which causes internal short-circuiting
Solution Approach 1:
The cathode layer is divided into multiple cathode subregions separated by gaps, and the anode layer is divided into multiple anode subregions separated by gaps. This segmentation prevents defect propagation across the entire layer, as defects are confined to individual subregions. The gaps act as isolation barriers that prevent continuous defect paths between electrodes.
Solution Approach 2:
Dielectric material is introduced as an intermediary substance to fill the gaps between cathode subregions and anode subregions. This dielectric material prevents direct electrical contact between electrodes while maintaining structural integrity, thereby preventing internal short-circuiting through defects without compromising ion transport through the electrolyte layer.
2Quantity of substance
If the cathode layer is made solid and continuous to maximize active material, then energy density is improved, but defect propagation affects the entire layer
Solution Approach 1:
The cathode layer is divided into multiple cathode subregions separated by gaps, reducing the total area occupied by cathode material compared to a solid continuous layer. However, this segmentation prevents defect propagation across the entire layer, as defects are confined to individual subregions. The gaps act as isolation barriers.
3Ease of manufacture
If manufacturing processes are simplified to reduce costs, then fabrication complexity is reduced, but manufacturing precision and defect control deteriorate
Solution Approach 1:
The segmented structure with gaps between subregions provides inherent defect isolation, improving manufacturing precision and yield. Even if defects occur during fabrication, they are confined to specific subregions rather than propagating across the entire electrode layer, thereby reducing waste and improving overall manufacturing efficiency.
Data Source
AI summary
Solid-state battery structures and methods of manufacturing solid-state batteries are disclosed. More particularly, embodiments relate to solid-state batteries having one or more subdivided electrode layers. Other embodiments are also described and claimed.