Battery Array Testing and Parallel Connection on Substrate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing battery devices are costly and have low manufacturing yields due to the complexity of connecting batteries in parallel, where a single defective battery can render the entire array inefficient or non-functional, especially during the separation and testing processes.
Innovation Solution
A method involving the deposition of electrically conductive layers on a substrate to form and test batteries in a matrix format, where functional batteries are connected in parallel using a second conductive layer, while defective batteries are isolated, ensuring identical battery production and optimizing energy storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are tested individually and then detached from the substrate for bonding to a new substrate, then functional batteries can be identified, but the manufacturing process becomes expensive and complex with low yields
Solution Approach 1:
The patent applies preliminary action by forming a complete electrical circuit on the substrate before depositing the battery-active layers. This allows batteries to be tested in situ while still attached to the substrate, eliminating the need for costly detachment and re-bonding operations. The circuit is prepared in advance so that testing can occur at an optimal stage in the manufacturing process.
Solution Approach 2:
The patent extracts the testing operation from the post-assembly stage and performs it earlier in the manufacturing process, while batteries are still on the substrate. This extraction of the testing function to an earlier stage enables identification of defective batteries before final assembly, allowing for selective removal of only defective units rather than requiring complete disassembly and reassembly.
2Quantity of substance
If batteries are connected in parallel to optimize energy storage capacity, then energy storage is maximized, but a single defective battery can render the entire array inefficient or non-functional
Solution Approach 1:
The patent performs preliminary testing of each battery before final parallel connection by measuring electrical parameters through the pre-formed circuit. This allows defective batteries to be identified and removed from the array before they can compromise the entire system. The testing occurs while batteries are still on the substrate, enabling selective elimination of faulty units while maintaining the parallel connection configuration for optimal energy storage.
3Ease of manufacture
If batteries are separated from the substrate after testing, then functional batteries can be reassembled, but damage during separation reduces manufacturing yields
Solution Approach 1:
The patent performs the separation action selectively and only for defective batteries after testing is complete. Functional batteries remain on the substrate and are not subjected to separation risks. The pre-formed electrical circuit enables identification of which batteries need separation, allowing the manufacturing process to proceed with minimal handling of functional units, thereby maximizing manufacturing yield while still enabling reassembly of good batteries.
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 simplifies the manufacturing process, increases yields, and ensures optimal battery efficiency by isolating defective batteries, thereby reducing costs and improving the quality and efficiency of the battery device.
Implementation Method 1
a first electrically conductive layer (1) is deposited on a support substrate (2)
Data Source
Figure 1~4
Figure 5~7
Figure 8~10
AI summary
The method of producing a device having batteries comprises the following successive steps carried out on a support substrate (2): - providing a support substrate (2) comprising a first electrically conducting layer (1) which forms a main face - simultaneously forming on the first electrically conducting layer (1) a plurality of batteries (3a, 3b, 3c, 3d), - testing the operation of the batteries (3a, 3b, 3c, 3d), so as to discriminate a first group of functional batteries (3a, 3b, 3d) and a second group of defective batteries (3c), - forming a second electrically conducting layer (7), electrically insulated from the first electrically conducting layer (1), the second electrically conducting layer (7) and the first electrically conducting layer (1) being configured so as to link in parallel only the functional batteries (3a, 3b, 3d).