3D-Structured Solid State Battery Interdigitated Electrodes
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Solution Overview
Problem
Conventional lithium-ion batteries face limitations in energy density and bulk/weight, which are not adequately addressed by existing thin film solid state batteries, particularly in terms of integration with device manufacturing processes and efficient cathode performance.
Innovation Solution
A thin film solid state battery is structured with interdigitated anode and cathode finger geometries separated by electrolyte, allowing for selective patterning and deposition of materials on a substrate, enhancing cathode efficiency and integration with existing manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional lithium-ion battery structure is used, then manufacturing process is simple, but energy density and weight are not optimized
Solution Approach 1:
The patent transitions from conventional planar battery architecture to a three-dimensional interdigitated finger geometry, where anode and cathode materials are arranged in alternating vertical fingers. This dimensional transformation increases the electrode surface area and active material volume within the same footprint, thereby improving energy density without proportionally increasing weight, while remaining compatible with existing thin-film deposition manufacturing processes
2Weight of moving object
If thin film solid state battery structure is used, then weight is reduced, but cathode efficiency and integration with manufacturing processes are not optimized
Solution Approach 1:
The interdigitated finger geometry transforms the conventional planar thin-film structure into a three-dimensional configuration with alternating anode and cathode fingers extending vertically. This dimensional change increases the cathode volume and active material content by a factor of three or more compared to planar structures of the same footprint, significantly improving cathode efficiency and capacity while maintaining the weight advantages of thin-film solid-state batteries
Solution Approach 2:
The battery is segmented into multiple discrete finger-like electrodes rather than using continuous planar layers. The anode and cathode are divided into alternating fingers separated by electrolyte, creating numerous independent electrochemical reaction zones. This segmentation increases the total active material volume and improves cathode efficiency while maintaining compatibility with sequential thin-film deposition processes
3Quantity of substance
If interdigitated finger geometry is implemented, then cathode volume and electrolyte surface area increase, but device complexity increases
Solution Approach 1:
The patent achieves increased cathode volume and electrolyte surface area by transitioning to a three-dimensional interdigitated finger geometry. While the physical structure becomes more complex, the manufacturing process remains relatively simple, utilizing sequential thin-film deposition techniques that are already established in the industry. The complexity is primarily geometric rather than process-related
Solution Approach 2:
The patent combines multiple functions into the interdigitated finger structure: the fingers serve as both current collectors and active electrodes, the electrolyte simultaneously separates anode and cathode while providing ion transport pathways, and the overall geometry provides both structural support and electrochemical functionality. This merging reduces the need for additional separate components, offsetting the geometric complexity
Data Source
AI summary
This disclosure relates to a battery and a method for its manufacture. One embodiment of the battery may include a three-dimensionally structured thin film solid state battery having interdigitated cathode and anode volumes, which are separated by an electrolyte material. In an example method, a cathode current collector layer and an anode current collector layer may be formed on a substrate. The cathode current collector layer and the anode current collector layer may include a cathode current collector area and an anode current collector area, respectively. A cathode layer may be formed on the cathode current collector layer and an anode layer may be formed on the anode current collector layer. An electrolyte layer may be formed on the substrate. The electrolyte layer may include an electrolyte area, which separates the anode current collector area and the cathode current collector area.