Thin Film Battery Adhesive Layer Notch Design
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Solution Overview
Problem
Solid-state battery structures and manufacturing methods require optimization to enhance energy density, particularly by reducing the vertical space occupied by non-power contributing elements in the cell stack.
Innovation Solution
Incorporating an intermediate adhesive layer with gaps or notches between electrochemical cells, where an anode current collector fills the gaps and has a similar thickness to the adhesive layer, allowing for efficient electrical contact and reduced z-height impact, while using a pre-formed pressure-sensitive adhesive for bonding without curing or treatment steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive layer is placed between electrochemical cells, then the cells are bonded together, but the vertical space (z-height) increases
Solution Approach 1:
The anode current collector is nested within a gap or notch in the adhesive layer, allowing the current collector to be partially embedded in the adhesive material. This nesting arrangement enables the current collector to make electrical contact with anode layers while minimizing the overall z-height contribution of the adhesive assembly, as the current collector occupies space within the adhesive layer rather than adding full thickness on top of it.
2Reliability
If the anode current collector is positioned between anode layers, then electrical contact is established, but the risk of electrical shorting to the cathode layer increases
Solution Approach 1:
The adhesive layer serves as an intermediary material between the anode current collector and the cathode layer. By positioning the current collector within a gap or notch in the adhesive layer, the adhesive material acts as a physical barrier and insulator that prevents direct electrical contact between the conductive current collector and the cathode layer, thereby eliminating the shorting risk while maintaining electrical connectivity to the anode layers.
3Strength
If the adhesive layer thickness is increased, then bonding strength improves, but the z-height and energy density are adversely affected
Solution Approach 1:
The current collector is nested within the adhesive layer structure, allowing the adhesive to provide bonding strength while the current collector utilizes the same vertical space for its electrical function. This nested configuration enables the use of a thinner adhesive layer than would be required if the current collector were positioned outside the adhesive, thereby reducing overall z-height and improving energy density while maintaining sufficient bonding strength.
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 configuration enhances energy density by minimizing vertical space usage and preventing electrical shorting, thereby improving the performance and safety of solid-state batteries.
Implementation Method 1
The adhesive layer may include a layer of pre-formed pressure sensitive adhesive that attaches to one or both of the anode layers of the two electrochemical cells
Data Source
AI summary
Solid-state battery structures and methods of manufacturing solid-state batteries, such as thin-film batteries, are disclosed. More particularly, embodiments relate to solid-state batteries having an intermediate adhesive layer between several electrochemical cells. In an embodiment, an anode current collector at least partially fills a notch in a periphery of the intermediate adhesive layer. Other embodiments are also described and claimed.