All-Solid-State Battery Stack Inspection for Short-Circuit Prevention
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Solution Overview
Problem
The existing methods for producing all-solid-state batteries do not effectively inspect each stack unit for insulation before stacking, leading to a high rate of defective products due to potential short circuits caused by foreign matter or insulative issues.
Innovation Solution
A method involving the formation of insulating layer-attached stack units, where a dielectric breakdown test is performed on each insulating layer to determine non-defective units, which are then assembled into an electrode member and case with a restraint member applying pressure less than the test pressure, ensuring the battery is less likely to experience short circuits during use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation inspection is performed only on the plurality of stack units as a whole after the stacking step, then the inspection process is simple, but there is a possibility that the plurality of stack units as a whole may be defective due to undetected short circuits
Solution Approach 1:
The patent divides the inspection process into two levels: individual stack unit inspection and group inspection. Each stack unit is equipped with its own insulating layer and undergoes individual dielectric breakdown testing. This segmentation allows defective units to be identified and excluded before final assembly, improving overall reliability without requiring complex inspection equipment for the entire batch.
Solution Approach 2:
The insulating layer is attached to each stack unit before the stacking step, and insulation inspection is performed on each individual unit beforehand. This preliminary action ensures that only non-defective stack units are stacked together, preventing defective units from being included in the final product while maintaining a relatively simple inspection process.
2Reliability
If a dielectric breakdown test is performed on each insulating layer with predetermined test pressure, then the insulating layers are thoroughly inspected for defects, but the test pressure may be higher than what is applied during actual battery use
Solution Approach 1:
The patent utilizes the parameter change of the insulating layer thickness under pressure. During the dielectric breakdown test, a predetermined test pressure higher than the actual use pressure is applied to compress the insulating layer to its minimum thickness. This ensures that if the insulating layer can withstand the test pressure and maintain its dielectric properties, it will definitely withstand the lower pressure during actual battery operation, providing thorough inspection while ensuring safety under use conditions.
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 significantly reduces the rate of defective products by ensuring the insulating layers are non-defective and applying appropriate pressure, making the battery less prone to short circuits under practical use conditions.
Implementation Method 1
performing a dielectric breakdown test on the insulating layer included in the insulating layer-attached stack unit, and determining that the insulating layer-attached stack unit is a non-defective product if no dielectric breakdown is present
Implementation Method 2
assembling a restraint member to the outside of the case to produce the all-solid-state battery... the restraint member applies to the insulating layer a pressure that is less than the test pressure in the dielectric breakdown test
Data Source
AI summary
A method of producing an all-solid-state battery includes forming an insulating layer-attached stack unit including an insulating layer and a stack unit that includes a positive electrode layer, a solid electrolyte layer and a negative electrode layer; performing a dielectric breakdown test on the insulating layer included in the insulating layer-attached stack unit, and determining that the insulating layer-attached stack unit is a non-defective product if no dielectric breakdown is present; forming an electrode member having both ends by disposing the two insulating layer-attached stack units at the both ends, the insulating layer-attached stack unit being determined to be a non-defective product; accommodating the electrode member in a case; and assembling a restraint member to the outside of the case to produce an all-solid-state battery.