All-Solid-State Battery Warping Control via Segmented Symmetric Stacking
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Solution Overview
Problem
The production of all-solid-state batteries faces challenges with warping issues in the stack, leading to increased production steps and inefficiencies, particularly when transferring the solid electrolyte layer onto the negative electrode active material layer, resulting in asymmetry and subsequent cracking.
Innovation Solution
A method involving the disposition of first and second electrode active material layers on both sides of collectors, followed by the placement of solid electrolyte layers and subsequent pressing to form battery units, which are then stacked, minimizing warping by ensuring even thickness and stress distribution across the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a positive electrode collector/positive electrode active material layer/solid electrolyte layer/negative electrode active material layer/negative electrode collector are combined and pressed, then the all-solid-state battery structure is formed, but warping occurs in the pressed stack requiring additional steps to minimize warping
Solution Approach 1:
The invention divides the battery structure into multiple segments with collectors positioned at both ends (first collector and second collector), creating a symmetric segmented structure that balances internal stresses and prevents warping during pressing operations
Solution Approach 2:
The invention introduces asymmetry by adding electrode active material layers on both sides of the first collector, creating an asymmetric distribution that balances the overall stack structure and eliminates warping tendencies caused by uneven pressure distribution
2Productivity
If the solid electrolyte layer is transferred onto the negative electrode active material layer, then the battery structure is assembled, but asymmetry and cracking occur due to warping
Solution Approach 1:
The invention performs preliminary actions by pre-assembling the complete symmetric structure with collectors at both ends and electrode layers on both sides before pressing, ensuring that the structure is pre-balanced to prevent warping and cracking during subsequent assembly steps
3Manufacturing precision
If additional steps are added to minimize warping, then stack stability is improved, but the number of production steps increases
Solution Approach 1:
The invention changes the structural parameters by positioning collectors at both ends and distributing electrode active material layers symmetrically on both sides, fundamentally altering the pressure distribution parameters during pressing to eliminate warping without requiring additional control steps
Data Source
AI summary
An objective of the invention is to provide a method for producing an all-solid-state battery with fewer steps for minimizing warping than in the prior art, and an all-solid-state battery with lower warping. This is achieved by a method comprising the steps of: (A) disposing a first electrode active material layer on both sides of a first collector to form a first electrode layer, (B) disposing a solid electrolyte layer on each of the first electrode active material layers, (C) disposing a second electrode active material layer and a second collector on the solid electrolyte layers, in such a manner that the second electrode active material layers contact with the solid electrolyte layers, (D) pressing a stack formed in steps (A) to (C), to form a battery unit, (E) repeating steps (A) to (D) to form a plurality of battery units, and (F) stacking the plurality of battery units.