Solid-State Cell Cathode Geometry for Faster Stack Connection
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Solution Overview
Problem
The manufacturing of solid-state electrochemical cells is time-consuming and prone to imperfections due to multiple steps in depositing cathode material, and existing methods to separate anode and cathode current collectors for preventing shorting are expensive and time-consuming.
Innovation Solution
A solid-state electrochemical cell with a sintered cathode layer, electrolyte layer, anode layer, anode current collector, and cathode current collector, where the sintered cathode layer has oblique surfaces allowing for easy electrical connection and reduced likelihood of shorting, and the cathode material is sintered in a single step to form a robust sheet that acts as a substrate for other layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple layers of cathode material are supplied to a substrate through multiple deposition steps, then a cathode of suitable thickness is achieved, but the manufacturing process becomes time-consuming and introduces imperfections such as unintended variations in layer thickness
Solution Approach 1:
The invention segments the cathode structure by forming discrete cathode segments on the substrate, where each segment corresponds to a separate active material deposition region. This segmentation allows for more controlled and uniform material deposition in each segment, reducing thickness variations while maintaining overall cathode thickness requirements.
Solution Approach 2:
The invention applies preliminary action by pre-forming the cathode structure with defined segments and thickness variations before final assembly. The cathode segments are prepared with specific thickness profiles in advance, allowing for optimized material deposition without requiring multiple iterative deposition steps during final cell manufacturing.
2Reliability
If chemical etching or laser ablation is performed on portions of the electrochemical cell to expose current collectors, then the anode and cathode current collectors are arranged apart to reduce shorting risk, but the process becomes expensive and time-consuming
Solution Approach 1:
The invention introduces asymmetry in the cell structure by deliberately designing different configurations for anode and cathode current collector exposure. The cathode current collector is exposed on lateral sides while the anode current collector remains covered or is exposed differently, creating an asymmetric arrangement that prevents shorting without requiring symmetric etching or ablation of both electrodes.
Solution Approach 2:
The current collector exposure is built into the cell structure during the lamination and assembly process rather than requiring post-assembly etching or ablation. The cathode current collector is exposed through the lateral sides of the cell stack during manufacturing, and this exposure configuration is maintained throughout operation, eliminating the need for time-consuming chemical etching or laser ablation steps.
3Ease of operation
If the cathode current collector is exposed on lateral sides of the cell, then electrical connection to other cells becomes easier with reduced shorting risk, but the cell structure becomes more complex
Solution Approach 1:
The exposed cathode current collector on the lateral sides serves multiple functions: it provides electrical connection interfaces for series/parallel cell configurations, acts as a structural element of the cell stack, and maintains separation between anode and cathode collectors to prevent shorting. This multi-functional design simplifies the overall cell structure despite the exposed configuration.
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 reduces manufacturing time, minimizes imperfections, and eliminates the need for costly processes like laser ablation or etching, enabling efficient and reliable electrical connection in battery stacks.
Implementation Method 1
the cathode material is sintered in a single step to form a robust sheet
Data Source
AI summary
Solid-state electrochemical cells are disclosed. In examples, the cell comprises a sintered cathode layer, an electrolyte layer, an anode layer arranged on at least part of the electrolyte layer, an anode current collector, and a cathode current collector. The sintered cathode layer comprises side surfaces having portions which extend in planes oblique to the plane in which the top and/or bottom surfaces of the sintered cathode layer extend. The electrolyte layer is arranged on at least one of these portions; the cathode current collector is arranged on at least another of these portions.