3D Battery Cell Stack Deposition for Scalable Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing methods for 3-D structured batteries, such as 3-D lithium-ion batteries, lack scalability and are complex.
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 by cycling through various workstations, with the option of using surrogate electrolyte materials that can be replaced with final electrolyte materials.
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 is insufficient
Solution Approach 1:
The manufacturing system is divided into multiple discrete workstations (first electrode workstation, first electrolyte workstation, second electrode workstation, second electrolyte workstation) that perform specific functions. This segmentation allows each station to be optimized independently and enables scalable production by adding or removing stations as needed.
Solution Approach 2:
The substrate serves multiple functions: it supports material deposition, provides structural integrity during manufacturing, and acts as a base for the battery cell stack. The cyclical approach allows the same substrate to be processed through multiple workstations in sequence, making the manufacturing system versatile and adaptable to different battery configurations.
2Productivity
If a cyclical station-based approach is used, then scalability is improved, but process complexity increases
Solution Approach 1:
The manufacturing process uses a cyclical approach where the substrate is repeatedly cycled through the same sequence of workstations. This periodic action simplifies control logic (the same process repeats) while enabling scalability (the cycle can be repeated any number of times to produce multiple battery cells or stacks).
Solution Approach 2:
The same workstation sequence is copied and repeated for each battery cell in the stack. Instead of designing a unique complex process for each cell, the system uses identical deposition sequences at each workstation, simplifying the overall process design while maintaining scalability.
3Productivity
If additive manufacturing is used for material deposition, then manufacturing efficiency is improved, but material layer separation control becomes more difficult
Solution Approach 1:
The deposition process is segmented into distinct workstations, each responsible for depositing a specific material layer (electrode or electrolyte). This segmentation ensures that each layer is deposited under optimized conditions with proper control over thickness, uniformity, and separation from adjacent layers, maintaining manufacturing precision while enabling efficient additive manufacturing.
Solution Approach 2:
The substrate acts as an intermediary that facilitates controlled layer deposition. By providing a stable, flat surface with appropriate surface properties, the substrate enables precise control over material layer formation and separation during the additive manufacturing process, ensuring that each layer is deposited accurately without unwanted mixing or contamination.
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 efficiency and flexibility in material deposition.
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.