3D Pillar Lithium Battery with Insulated Current Collector
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Solution Overview
Problem
Existing lithium battery designs face challenges in achieving high energy densities while minimizing electrochemically inactive electronic current collectors, which can lead to stress and reduced cycle life in high-aspect ratio structures, especially when optimized for portable electronics and electric vehicles.
Innovation Solution
A method for manufacturing a 3D thin-film battery with a substrate current collector featuring elongate, aligned conductive pillars, a solid state electrolyte, and a top current collector shielded by an insulator, allowing for increased specific charge collecting area and power with a robust design, using a conformal multilayer coating to enhance performance without compromising functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-aspect ratio structures are used to increase specific charge collecting area, then charge collecting capacity is improved, but stress and cycle life are reduced
Solution Approach 1:
The battery structure is divided into multiple pillars separated by insulating material, creating discrete current collection zones. This segmentation reduces stress propagation between pillars and prevents dendrite formation at pillar interfaces, thereby improving cycle life while maintaining high charge collecting area through the multiplied pillar surfaces.
Solution Approach 2:
An insulating material layer is introduced between the conductive substrate and the electrode material, serving as an intermediary that mechanically decouples the high-aspect ratio pillars from the substrate. This intermediary layer prevents stress transfer and dendrite propagation while allowing ionic transport, thus preserving both the high surface area benefit and the structural integrity for long cycling.
2Quantity of substance
If 3D micro-patterned structures are used to increase energy density, then charge capacity is improved, but device complexity increases
Solution Approach 1:
The current collector is transformed from a planar 2D structure to a 3D micro-patterned architecture with vertical pillars. This dimensional transition increases the effective surface area for charge collection by utilizing the vertical dimension, thereby enhancing charge capacity without proportionally increasing the horizontal footprint or overall device complexity.
Solution Approach 2:
The conductive substrate is designed with a porous or micro-patterned structure containing arrays of pillars with controlled spacing. This porous architecture provides high surface area-to-volume ratio for electrochemical reactions while maintaining structural integrity and allowing efficient ion transport through the porous network, achieving high charge capacity with manageable structural complexity.
3Use of energy by moving object
If lithium metal anode is used to achieve high energy density, then energy density is improved, but dendrite formation and safety issues worsen
Solution Approach 1:
The insulating material is selectively positioned at the tips and between the pillars, creating local quality variations in the battery structure. This localized insulation prevents lithium dendrite formation at critical interfaces while allowing uniform lithium plating on the pillar surfaces, thus maintaining high energy density with improved safety by eliminating dendrite propagation pathways.
Solution Approach 2:
The insulating barrier layer is pre-installed on the conductive substrate before lithium metal deposition. This beforehand cushioning prevents dendrite formation by blocking potential nucleation sites and providing a uniform interface for lithium plating, thereby preventing safety issues before they can develop during battery cycling while preserving high energy density.
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
This approach results in a battery with enhanced charge collecting capacity, reduced stress, and improved cycling stability by directing ion and electron flow efficiently, thereby increasing the energy density and extending the battery's lifespan.
Implementation Method 1
a solid state electrolyte layer provided on the first electrode layer
Implementation Method 2
forming elongate and aligned electrically conductive structures on the substrate face with upstanding walls
Implementation Method 3
a top current collector layer in electrical contact with the second electrode layer, wherein the second electrode layer is shielded from the conductive structure by an insulator covering a part of said conductive structure
Data Source
AI summary
A method of manufacturing a battery with a substrate current collector, wherein the method comprises: forming elongate and aligned electrically conductive structures on the substrate face with upstanding walls; wherein the walls are formed with a first electrode layer covering said walls, and a solid state electrolyte layer provided on the first electrode layer; and wherein a second electrode layer is formed by covering the electrolyte layer with an electrode layer; and forming a top current collector layer in electrical contact with the second electrode layer, wherein the second electrode layer is shielded from the conductive structure by an insulator covering a part of said conductive structure adjacent an end side thereof.