All-Solid Battery Substrate Thinning for Thin Electrolyte
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Solution Overview
Problem
Existing all-solid batteries and microbatteries face challenges in producing thin, high-quality solid electrolyte layers due to surface roughness of the substrate, leading to flaws and increased thickness, which limits their energy storage capacity and high-power operation performance.
Innovation Solution
A method involving the production of an all-solid battery where a substrate made of active material is thinned to form a second electrode, allowing for uniform and thinner solid electrolyte layers without the need to fill flaws, using techniques like ion implantation and substrate splitting to create an embrittlement zone and separate the second electrode, thereby reducing the overall thickness and improving electronic insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrolyte layer thickness is increased to fill surface flaws, then the electronic insulation quality improves, but the battery's energy storage capacity and power characteristics deteriorate
Solution Approach 1:
The substrate surface is prepared in advance by creating an embrittlement zone through ion implantation or laser treatment before electrolyte deposition. This preliminary action creates a controlled separation plane that allows the substrate to be thinned to form a discrete second electrode, enabling thin electrolyte layers without surface flaw-related electronic leaks
Solution Approach 2:
The substrate is segmented into two separate electrodes by creating an embrittlement zone and subsequently thinning the substrate. This segmentation transforms the continuous substrate into distinct first and second electrodes with a thin electrolyte layer in between, resolving the contradiction by eliminating the need for thick electrolyte to cover surface flaws
2Manufacturing precision
If the electrolyte layer thickness is increased to cover surface roughness, then the homogeneity of the electrolyte improves, but the overall battery thickness increases
Solution Approach 1:
The substrate undergoes preliminary treatment through ion implantation or laser processing to create an embrittlement zone at a controlled depth. This allows subsequent thinning to produce a thin second electrode with a clean, uniform surface that does not require thick electrolyte coverage to mask surface roughness
Solution Approach 2:
The physical and chemical parameters of the substrate surface are changed through ion implantation or laser treatment, creating an embrittlement zone with distinct properties. This parameter change enables precise control over the second electrode thickness and surface quality, allowing thin electrolyte layers with high homogeneity
3Length of stationary object
If the substrate is thinned to form a discrete second electrode, then the electrolyte layer can be made thinner, but the manufacturing process complexity increases
Solution Approach 1:
Traditional mechanical thinning methods are replaced with ion implantation or laser processing to create the embrittlement zone. These methods provide more precise control over the thinning process and embrittlement depth, enabling thinner electrolyte layers while maintaining manufacturing feasibility through standardized processes
Solution Approach 2:
An embrittlement zone is introduced as an intermediary structure between the substrate and the thinning process. This intermediary layer facilitates controlled separation and thinning, making the overall process more manageable and repeatable despite the added steps
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 the production of batteries with thinner electrolytes, improved power characteristics, reduced thickness, and flexibility, while allowing for substrate reuse, thus lowering production costs and enhancing energy storage capacity.
Implementation Method 1
production of a first electrode in contact with the electrolyte; thinning of the substrate, such that at least a remaining proportion of the substrate, in contact with the solid electrolyte layer, forms a second electrode
Implementation Method 2
The electrolyte is permeable to this ion flow, and electronically insulates the electrodes to prevent the electrochemical cell being short-circuited. The solid electrolyte constitutes an insulating material which is more effective than one in liquid form. For example, an electrolyte made from solid LiPON is characterised by an insulation of less than 10−13 S/cm
Data Source
AI summary
A method for the production of a battery includes at least production, against a substrate made of a material able to form an electrode, of at least one solid electrolyte layer, production of a first electrode in contact with the electrolyte, and thinning the substrate such that at least a remaining proportion of the substrate, in contact with the solid electrolyte layer, forms a second electrode.