All-Solid-State Battery and Method of Manufacturing the Same

Patent metadata

Field	Value
Publication number	US-2022384785-A1
Application number	US-202117524385-A
Country	US
Kind code	A1
Filing date	Nov 11, 2021
Priority date	May 28, 2021
Publication date	Dec 1, 2022
Grant date	—

Abstract

A method of manufacturing an all-solid-state battery includes forming an anode active material layer on surfaces of an anode current collector, forming a first solid electrolyte layer covering exposed surfaces of the anode active material layer to form a symmetrical electrode structure, pressing the structure at a preliminary pressing pressure lower to form an anode, forming a cathode active material layer on a surface of cathode current collectors, the cathode active material layer being smaller than the cathode current collectors, forming a second solid electrolyte layer covering the cathode active material layers and the cathode current collectors to form first and second cathodes, forming a laminate by laminating the cathodes on opposite surfaces of the anode, the second solid electrolyte layers of the cathodes facing the anode, and pressing the laminate at the final pressing pressure.

First claim

What is claimed is:

1 . A method of manufacturing an all-solid-state battery, the method comprising:
forming an anode active material layer on opposite surfaces of an anode current collector, the anode active material layer being smaller than the anode current collector and the anode current collector being exposed to an outer periphery; forming a first solid electrolyte layer on the anode active material layer on the opposite surfaces of the anode current collector to cover exposed surfaces of the anode active material layer and to form a symmetrical electrode structure; pressing the symmetrical electrode structure at a preliminary pressing pressure lower than a final pressing pressure to form an anode; forming a cathode active material layer on a first surface of a cathode current collector, the cathode active material layer being smaller than the cathode current collector and the cathode current collector being exposed to an outer periphery; forming a second solid electrolyte layer covering the cathode active material layer and the cathode current collector on the outer periphery to form a first cathode having the same planar shape as the anode; forming a second cathode substantially identical to the first cathode; forming a laminate by laminating the first cathode and the second cathode on opposite surfaces of the anode, respectively, the second solid electrolyte layers of the first cathode and the second cathode facing the anode; and pressing the laminate at the final pressing pressure.

2 . The method according to claim 1 , wherein:
forming the first cathode comprises attaching a first resin sheet to a second surface of the cathode current collector prior to forming the cathode active material layer on the first surface of the cathode current collector; forming the second cathode comprises forming the second cathode with a second resin sheet; and pressing the laminate at the final pressing pressure comprises pressing the first cathode with the first resin sheet attached and the second cathode with the second resin sheet attached.

3 . The method according to claim 2 , wherein pressing the laminate at the final pressing pressure is performed in a press die, the press die comprising upper and lower dies each comprising an elastic body on an outer peripheral wall of a groove configured to accommodate the anode and the first and second cathodes after forming the laminate.

4 . The method according to claim 3 , wherein the elastic body prevents lateral deformation of the first cathode, the second cathode, and the anode after forming the laminate.

5 . The method according to claim 2 , further comprising detaching the first resin sheet from the first cathode and detaching the second resin sheet from the second cathode after pressing the laminate at the final pressing pressure.

6 . The method according to claim 1 , wherein:
forming the first cathode comprises attaching a first resin sheet to a second surface of the cathode current collector; forming the second cathode comprises forming the second cathode with a second resin sheet; and pressing the laminate at the final pressing pressure comprises pressing the first cathode with the first resin sheet attached and the second cathode with the second resin sheet attached.

7 . The method according to claim 1 , wherein the preliminary pressing pressure is 100 MPa or less and the final pressing pressure is 500 MPa or more.

8 . A method of manufacturing an all-solid-state battery, the method comprising:
forming an anode, wherein forming the anode comprises:
forming an anode active material layer on opposite surfaces of an anode current collector, the anode active material layer being smaller than the anode current collector and the anode current collector being exposed to an outer periphery;
forming a first solid electrolyte layer on the anode active material layer on the opposite surfaces of the anode current collector to cover exposed surfaces of the anode active material layer to form a symmetrical electrode structure;
pressing the symmetrical electrode structure at a preliminary pressing pressure lower than a final pressing pressure; and
punching the symmetrical electrode structure to remove a peripheral area of the symmetrical electrode structure;
forming first and second cathodes each having a same planar shape as the anode, wherein forming the first and second cathodes comprises:
forming a cathode active material layer on a first surface of a cathode current collector, the cathode active material layer being smaller than the cathode current collector and the cathode current collector being exposed to an outer periphery; and
forming a second solid electrolyte layer covering the cathode active material layer and the cathode current collector on the outer periphery;
forming a laminate by laminating the first cathode and the second cathode on opposite surfaces of the anode, respectively, the second solid electrolyte layers of the first cathode and the second cathode facing the anode; and pressing the laminate at the final pressing pressure.

9 . The method according to claim 8 , wherein:
forming the first and second cathodes further comprises attaching a resin sheet to a second surface of the cathode current collector prior to forming the cathode active material layer on the first surface of the cathode current collector; and pressing the laminate at the final pressing pressure comprises pressing the first and second cathodes with the resin sheet attached.

10 . The method according to claim 9 , wherein pressing the laminate at the final pressing pressure is performed in a press die, the press die comprising upper and lower dies each comprising an elastic body on an outer peripheral wall of a groove configured to accommodate the anode and the first and second cathodes after forming the laminate.

11 . The method according to claim 10 , wherein the elastic body prevents lateral deformation of the first cathode, the second cathode, and the anode after forming the laminate.

12 . The method according to claim 9 , further comprising detaching the resin sheet from the first and second cathodes after pressing the laminate at the final pressing pressure.

13 . The method according to claim 8 , wherein:
forming the first and second cathodes further comprises attaching a resin sheet to a second surface of the cathode current collector; and pressing the laminate at the final pressing pressure comprises pressing the first and second cathodes with the resin sheet attached.

14 . The method according to claim 8 , wherein forming the first and second cathodes further comprises cutting and removing ends of the first and second cathodes.

15 . The method according to claim 8 , wherein the preliminary pressing pressure is 100 MPa or less.

16 . The method according to claim 15 , wherein the final pressing pressure is 500 MPa or more.

17 . An all-solid-state battery comprising:
an anode comprising:
an anode current collector;
first and second anode active material layers on opposite surfaces of the anode current collector, respectively, wherein each of the first and second anode active material layers is smaller than the anode current collector; and
first and second solid electrolyte layers covering the first and second anode active material layers and the anode current collector on an outer periphery, respectively; and
first and second cathodes on opposite sides of, and having a same planar shape as, the anode, each of the first and second cathodes comprising:
a cathode current collec

Assignees

• Hyundai Motor Co Ltd
• Kia Corp

Inventors

• Sasaki Yuki
• Yoon Yong Sub
• Tsuchiya Hajime
• Takase Hironari

Classifications

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M10/0562 Primary

  Solid materials · CPC title

• H01M4/0433

  Molding · CPC title

• H01M4/366 Primary

  as layered products · CPC title