Cylindrical Solid-State Electrode Assembly With Resilient Polymer Support

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Solution Overview

Problem

Existing lithium ion batteries face safety concerns due to the use of flammable organic electrolytes, which can lead to fires or explosions in the event of a short-circuit, and there is a need for high-energy-density and high-safety batteries suitable for automotive applications.

Innovation Solution

A cylindrically wound electrode assembly comprising a first and second solid electrolyte layer with a positive and negative electrode layer, where the electrodes include composite substrates with resilient polymer films, enhancing structural integrity and safety, and a cylindrical casing that houses this assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If flammable organic electrolytes are used in lithium ion batteries, then energy density is improved, but safety deteriorates due to fire or explosion risks

Engineering Contradiction:

Improveenergy densityVSAvoidsafety

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent changes the physical state of the electrolyte from liquid (flammable) to solid (non-flammable), fundamentally altering the safety parameter while maintaining ionic conductivity. This state change eliminates the fire hazard associated with organic electrolytes while preserving the high energy density characteristics of lithium ion batteries.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite structures including solid electrolyte layers combined with electrode materials, and resilient polymer films integrated with metal layers in the negative electrode substrate. These composite materials provide both the necessary electrochemical performance for high energy density and the mechanical properties for enhanced safety and structural integrity.

Inventive Principle:

Principle #40Composite materials

2Reliability

If solid electrolyte layers are used instead of liquid electrolytes, then safety is improved by eliminating fire risks, but device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery structure is segmented into distinct functional layers including solid electrolyte layers, electrode layers, and composite substrates. This segmentation allows each component to be optimized independently for its specific function while maintaining overall system safety and performance, making the complex solid-state structure more manageable and manufacturable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The solid electrolyte layers serve multiple functions: they act as ionic conductors, physical separators between electrodes, and safety barriers against thermal runaway. This multi-functionality reduces the need for additional separate safety components, thereby managing device complexity while maintaining enhanced safety.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If resilient polymer films are used in electrode substrates, then structural integrity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent utilizes thin resilient polymer films as part of the electrode substrate structure. These flexible films provide necessary mechanical strength and elasticity to accommodate volume changes during charge-discharge cycles while maintaining structural integrity. The thin-film approach minimizes material usage and simplifies integration into the overall battery structure.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The electrode substrates are constructed as composites combining resilient polymer films with metal layers. This composite structure synergistically combines the flexibility and elasticity of polymers with the conductivity and strength of metals, achieving superior structural integrity while maintaining manufacturability through established composite material processing techniques.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4668353A1Electrode assembly and cylindrical all-solid-state battery including the same

Publication Date: 2025.12.24 SAMSUNG SDI CO LTD

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AI summary

Cylindrically wound electrode assemblies and all-solid-state batteries including the electrode assembly are provided. The cylindrically wound electrode assembly includes a first solid electrolyte layer, a positive electrode layer, a second solid electrolyte layer, and a negative electrode layer. The first solid electrolyte layer, the positive electrode layer, the second solid electrolyte layer, and the negative electrode layer are sequentially arranged along a radial direction of the electrode assembly. The negative electrode layer includes a negative electrode substrate, and a first negative electrode coating layer between the negative electrode substrate and the second solid electrolyte layer. The negative electrode substrate includes a negative electrode support layer, a first negative electrode metal layer on a first surface of the negative electrode support layer, and a second negative electrode metal layer on a second surface of the negative electrode support layer. The negative electrode support layer includes a resilient polymer film.