3D Battery Cell Stacking via Cyclical Layer Deposition
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Solution Overview
Problem
Current manufacturing methods for 3-D structured batteries, such as 3-D lithium-ion batteries, lack scalability and complexity, hindering efficient production.
Innovation Solution
A cyclical, station-based approach using additive manufacturing techniques to deposit layers of electrode and electrolyte materials on a substrate, forming a battery cell stack through repeated cycles, with optional use of surrogate electrolyte layers that are later replaced by final electrolyte material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for 3-D structured batteries, then manufacturing complexity is reduced, but scalability and production efficiency are insufficient
Solution Approach 1:
The manufacturing process is divided into discrete cyclical steps including depositing electrode material, depositing electrolyte material, and forming individual battery cells. Each step is independently executable and can be repeated to form stacks of multiple battery cells, enabling scalable production while maintaining process simplicity
Solution Approach 2:
The patent employs a cyclical manufacturing approach where the layer deposition sub-process is repeated multiple times to form stacks of battery cells. This periodic action allows for systematic production scaling without increasing overall process complexity, as each cycle follows the same standardized sequence of depositing electrode and electrolyte materials
2Quantity of substance
If 3-D structured battery design is implemented, then energy density and performance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent transitions from traditional 2-D planar battery structures to 3-D structured batteries by stacking multiple battery cells vertically. This dimensional change increases energy density by utilizing vertical space more efficiently, while the cyclical manufacturing process maintains simplicity by repeatedly forming identical cell structures in the third dimension
Solution Approach 2:
The manufacturing process nests multiple battery cells within a single stack structure, with each cell containing electrodes and electrolyte layers. This nested arrangement achieves high energy density by packing multiple functional units into a compact 3-D configuration, while the standardized cyclical production method keeps manufacturing complexity manageable
3Productivity
If multiple battery cells are formed in a stack, then productivity increases, but process complexity increases
Solution Approach 1:
The cyclical process establishes a standardized sequence of operations that is executed repeatedly: depositing electrode material, depositing electrolyte material, and forming complete battery cells. This preliminary structuring of the manufacturing sequence enables scalable production of cell stacks without proportionally increasing process complexity, as each cycle follows the same pre-defined pattern
Solution Approach 2:
The layer deposition sub-process serves multiple functions across different cycles: it forms individual battery cells, creates complete stacks through repetition, and maintains consistent quality across all cells. This universal process design achieves high productivity while minimizing complexity by using the same equipment and procedures for all production stages
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
Enables scalable and efficient manufacturing of 3-D structured batteries, allowing for the formation of a battery cell stack with improved production efficiency and flexibility.
Implementation Method 1
A cyclical, station-based approach using additive manufacturing techniques to deposit layers of electrode and electrolyte materials on a substrate
Data Source
AI summary
In one aspect, a method for manufacturing a battery includes forming a battery cell relative to a substrate using a layer-deposition sub-process, with the layer-deposition sub-process including: depositing a layer of first electrode material relative to the substrate; depositing a first layer of electrolyte material on top of the layer of first electrode material; depositing a layer of second electrode material on top of the first layer of electrolyte material; and depositing a second layer of electrolyte material on top of the layer of second electrode material. Additionally, the method includes cycling through the layer-deposition sub-process one or more additional times to form one or more additional battery cells relative to the substrate, with each additional battery cell being formed on top of a previously formed battery cell such that a battery cell stack is created relative to the substrate.