All-Solid-State Battery and Manufacturing Method Thereof

All-Solid-State Battery with High-Interface 3D-Printed Interdigitated Tubular Protrusions

This technology enhances the energy density and ionic conductivity of all-solid-state batteries by implementing an interdigitated structure. It features 3D-printed pillar or tubular protrusions on two current collectors that face each other, encapsulated by a solid electrolyte.

Conventional all-solid-state batteries suffer from low ionic conductivity in the solid electrolyte and uneven contact between the electrode and electrolyte, leading to high resistance and actual capacities significantly lower than theoretical limits. Thin-film structures also face inherent limitations in increasing energy density.

This technology utilizes 3D printing to create two active material structures with tubular protrusions 10–100 µm thick, arranged to interlock alternately in the width direction. This maximizes the interfacial area and shortens the lithium-ion diffusion path. Applicable to next-generation electric vehicle all-solid-state cells and micro-batteries for small IoT devices, it increases capacity per unit area through 3D electrodes within a small footprint and reduces interfacial impedance.

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Key Features:

• A first active material structure comprising a plurality of first protrusions disposed on a first current collector and protruding toward a second current collector
• A second active material structure comprising a plurality of second protrusions disposed on a second current collector and protruding toward the first current collector
• Tubular protrusions with inner and outer surfaces, where first-1 protrusions, second protrusions, and first-2 protrusions are arranged alternately in the width direction
• A solid electrolyte that fills the space between the first and second active material structures and encapsulates both structures

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