Stacked Solid-State Battery Insulating Layer for Crack Prevention
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Solution Overview
Problem
Conventional solid-state batteries experience cracking at the interface between insulating layers due to differences in material composition and stress concentration, leading to reduced battery capacity and performance.
Innovation Solution
The battery design incorporates an insulating layer with thicker end portions to distribute stress and prevent cracking, featuring a gradual thickness increase towards the end faces and optional cavity portions filled with different materials to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform thickness insulating layer is used between battery elements, then the manufacturing process is simple, but cracks occur at the end portions due to stress concentration
Solution Approach 1:
The insulating layer is designed with non-uniform thickness, where the end portions have greater thickness than the central portion. This local variation in geometry distributes stress more evenly at the critical end portions, preventing crack initiation while maintaining manufacturing feasibility through conventional sintering processes.
2Reliability
If the insulating layer has thicker end portions, then stress distribution and crack prevention are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The thickness parameter of the insulating layer is varied systematically, with the end portions having a greater thickness than the central portion. This parameter change optimizes stress distribution while the thickness ratio and transition gradients are controlled to remain within achievable tolerances for conventional manufacturing processes.
3Strength
If cavity portions are filled with different materials, then joint strength is enhanced, but the device complexity increases
Solution Approach 1:
The cavity portions within the insulating layer are filled with materials having different physical properties from the insulating layer matrix. This composite structure enhances joint strength at the battery element interfaces by providing mechanical interlocking and stress distribution, while the filling process can be integrated into the existing sintering manufacturing workflow.
Data Source
AI summary
A solid-state battery having two or more stacked battery elements, each battery element including one or more battery constituent units in which a positive electrode layer and a negative electrode layer oppose each other with a solid electrolyte layer between the positive electrode layer and the negative electrode layer; and an insulating layer interposed between adjacent battery elements of the two or more stacked battery elements, wherein at least one end portion of the insulating layer has a thickness greater than a thickness of a central portion of the insulating layer in a sectional view thereof.