Solid-State Battery Transfer Layer With Binder Gradient Adhesion
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Solution Overview
Problem
Existing methods for producing all solid state batteries face challenges in improving transfer efficiency, particularly in forming layers such as the cathode active material layer, solid electrolyte layer, and anode active material layer using a transfer method.
Innovation Solution
A method involving a transfer layer with a binder concentration gradient is used, where the binder concentration is higher on the surface opposite to the transfer foil compared to the surface on the transfer foil side, enhancing adhesion and transfer efficiency during the production of all solid state batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a transfer method is used to form active material layers and solid electrolyte layers, then manufacturing efficiency is improved, but transfer efficiency deteriorates due to insufficient adhesion
Solution Approach 1:
The binder concentration is made non-uniform within the transfer layer, with higher concentration at specific surfaces. This local quality variation enhances adhesion at critical interfaces during the transfer process, resolving the contradiction between manufacturing efficiency and transfer efficiency by optimizing binder distribution where it is most needed.
Solution Approach 2:
The binder concentration parameter is changed from uniform to gradient distribution. By controlling the binder concentration to be higher at one or both surfaces compared to the interior, the transfer layer achieves improved adhesion properties during transfer while maintaining manufacturing efficiency through the transfer method.
2Strength
If binder concentration is increased to improve adhesion, then interlayer adhesion is improved, but transfer efficiency deteriorates due to excessive binder on the transfer foil side
Solution Approach 1:
Instead of uniformly increasing binder concentration throughout the transfer layer, the invention applies local quality by concentrating binder at specific surfaces (one or both surfaces) while maintaining lower concentration in the interior. This localized binder enrichment improves interlayer adhesion at critical interfaces without creating excessive binder on the transfer foil side, thus maintaining transfer efficiency.
Solution Approach 2:
The binder concentration parameter is spatially differentiated within the transfer layer. By creating a concentration gradient where surface binder concentration exceeds interior concentration, the invention optimizes both adhesion strength and transfer efficiency, avoiding the trade-off that would result from uniform binder enrichment.
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 approach effectively suppresses transfer failures and improves the interlayer adhesion in all solid state batteries, leading to enhanced transfer efficiency and reduced battery resistance.
Implementation Method 1
the binder concentration of a surface portion on opposite side to the transfer foil is higher than a binder concentration of a surface portion on the transfer foil side
Data Source
AI summary
A method for producing an all solid state battery including a first current collector, a first active material layer, a solid electrolyte layer, a second active material layer and a second current collector stacked in this order, the method comprising: a transferring step of transferring a transfer layer onto the first current collector by using a transfer member including a transfer foil and the transfer layer, the transferring step being included in a step of forming at least one layer of the first active material layer, the solid electrolyte layer, and the second active material layer, and the transfer layer includes a binder, and in a thickness direction, a binder concentration of a surface portion on opposite side to the transfer foil is higher than a binder concentration of a surface portion on the transfer foil side.