Battery Component Layer Deposition With Electrically Floating Substrates
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Solution Overview
Problem
The deposition of component layers on substrates with electrically conductive or semi-conductive pathways can reduce the concentration of charge-carrying metal species in battery cells, leading to decreased capacity and increased resistance.
Innovation Solution
Avoiding the creation of electrically conductive or semi-conductive pathways from the deposition surface into the holding structure during the plasma deposition process, allowing the substrate to be electrically floating and preventing pathway extension into the holding structure, which enables the continued use of conductive or semi-conductive support layers and unpatterned current collectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrically conductive or semi-conductive pathways extend through the substrate into the holding structure during plasma deposition, then the substrate can be held in position, but the concentration of charge-carrying metal species in battery component layers is reduced
Solution Approach 1:
The holding structure is segmented into electrically insulating contact sites that physically hold the substrate without creating continuous conductive pathways. The substrate is divided into regions where electrical pathways are terminated at the substrate surface, separating the mechanical holding function from the electrical conduction path.
Solution Approach 2:
Electrically insulating materials are introduced as intermediary layers between the conductive substrate pathways and the holding structure. These insulating intermediaries prevent charge leakage while maintaining mechanical support, allowing the substrate to be held without extending conductive pathways into the holding structure.
2Ease of manufacture
If plasma deposition is used to deposit battery component layers, then layer formation is achieved, but charge-carrying metal species migrate causing reduced capacity and increased resistance
Solution Approach 1:
The conductive pathways are deliberately terminated at the substrate surface before plasma deposition begins, creating a preliminary condition that prevents charge-carrying metal species from migrating to the holding structure during deposition. This preliminary configuration counteracts the harmful migration effect that would otherwise occur during the plasma deposition process.
Solution Approach 2:
The plasma deposition process, which normally causes charge carrier migration and harm to battery performance, is converted into a beneficial process by ensuring that no conductive pathways exist for migration. The same plasma process that deposits layers is now safe because the harmful migration path has been eliminated through the insulating contact sites.
3Strength
If conductive support layers are used for mechanical support, then substrate strength is improved, but electrical pathways extend into the holding structure reducing battery performance
Solution Approach 1:
The conductive support layer is segmented into regions that provide mechanical strength and regions where electrical pathways are intentionally terminated. The support layer maintains its conductive properties for mechanical stability while contact sites are designed to interrupt electrical continuity, allowing simultaneous achievement of structural strength and electrical isolation.
Solution Approach 2:
Different regions of the substrate are given different electrical properties: the bulk substrate maintains conductivity for mechanical support, while the contact sites with the holding structure are made electrically insulating. This local differentiation allows the substrate to provide strength through its conductive bulk while preventing charge migration at the interface with the holding structure.
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 maintains the integrity of charge-carrying metal species, enhancing the capacity and reducing resistance in battery cells, as demonstrated by improved Raman spectra, thickness measurements, and battery cycling results.
Implementation Method 1
the depositing comprises forming a plasma within the deposition chamber
Data Source
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Figure 3(a)~3(b)
AI summary
A method is provided for fabricating a component material for a battery cell. The method comprises the steps of: providing a partially-fabricated battery cell, the partially-fabricated battery cell comprising a substrate having a planar deposition surface consisting of a first face of the substrate and a first battery component layer provided on the planar deposition surface, the substrate having a plurality of further surfaces, the planar deposition surface and the plurality of further surfaces defining the body of the substrate therebetween; wherein: the first battery component layer contains charge-carrying metal species and has an exposed surface; one or more electrically conductive or semi-conductive pathways extend through at least a portion of the substrate, each of the one or more pathways connecting the planar deposition surface to one of the plurality of further surfaces; and the partially-fabricated battery cell is held in position within a deposition chamber by a holding structure and each site of connection between one of the one or more pathways and the holding structure is electrically insulating; the method further comprising the step of depositing a second battery component layer on the first battery component layer, wherein the depositing comprises forming a plasma within the deposition chamber.