All-Solid-State Battery Electrode Folding for Precise Stacking
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Solution Overview
Problem
The manufacturing of all-solid-state batteries faces challenges in stacking and aligning electrodes due to porosity issues and limited scalability, particularly when using sulfide-based solid electrolytes, which results in shorter lifetimes and lower output compared to conventional liquid electrolyte batteries.
Innovation Solution
A method involving the preparation of electrode bending substrates with alternating single-sided and double-sided electrodes, where a solid electrolyte layer is applied to prevent contact between electrodes, allowing for alternate folding and stacking, followed by high-temperature pressing to form a stable electrode laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sulfide-based solid electrolyte is used to achieve high ionic conductivity, then lithium-ion conductivity is improved, but lifetime and output are reduced due to higher electric resistance between electrodes
Solution Approach 1:
A buffer layer is introduced as an intermediary between the sulfide-based solid electrolyte and the electrodes. This buffer layer mediates the interaction by reducing direct contact and interface resistance, thereby improving output and lifetime while preserving the high ionic conductivity of the sulfide electrolyte through its inherent fast ion conduction properties
2Manufacturing precision
If hydrostatic pressure method is used to pressurize the battery, then interface contact between electrodes and electrolyte is improved, but the size of pressurable cell is limited by chamber size
Solution Approach 1:
The battery structure is segmented into modular components with the buffer layer divided into multiple sections that can be independently positioned. This segmentation allows the assembly to be constructed in stages, enabling better interface contact through controlled placement while accommodating larger overall battery sizes that exceed single chamber limitations
Solution Approach 2:
The buffer layer is designed with three-dimensional structural features including protrusions and recesses that enable pressurization from multiple directions. This dimensional approach allows effective interface contact to be achieved without relying solely on single-direction hydrostatic pressure, thereby overcoming chamber size limitations
3Productivity
If roll-to-roll pressurization method is used for manufacturing, then production efficiency is improved, but the battery interior becomes porous and interface contact becomes difficult
Solution Approach 1:
The buffer layer is pre-formed with specific structural features (protrusions and recesses) before the final assembly process. This preliminary structuring ensures that when roll-to-roll pressurization is applied, the interface contact is already optimized, preventing porosity formation while maintaining the benefits of high-speed continuous manufacturing
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 method simplifies the manufacturing process, enables more electrodes to be stacked in desired sizes, facilitates accurate alignment, and improves the scalability and performance of all-solid-state batteries by preventing electrode contact and enhancing ionic conductivity.
Implementation Method 1
a solid electrolyte layer covering an entire electrode is formed on at least one of the first electrode bending substrate or the second electrode bending substrate to prevent the first electrode and the second electrode from contacting each other
Implementation Method 2
pressing an outermost side of the electrode laminate at a pre-determined temperature
Data Source
AI summary
The present disclosure relates to a method of manufacturing an all-solid-state battery which has a simple manufacturing process, can stack more electrodes in a desired size, and also facilitates alignment between electrodes, and an all-solid-state battery manufactured thereby.