3D Battery Porous Dielectric Separator Deposition
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Solution Overview
Problem
Existing lithium battery technologies face challenges in effectively incorporating a separator in three-dimensional battery architectures, which limits their energy and power density, active material utilization, and reliability compared to two-dimensional designs.
Innovation Solution
The method involves fabricating a structural layer with electrodes protruding from it, followed by depositing a porous dielectric material as a separator using techniques such as sub-ambient pressure/suction, spin-on dielectric, electrophoretic deposition, or chemical vapor deposition, allowing for a conformal and stress-reduced separator integration in three-dimensional battery structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separator is incorporated in three-dimensional battery architectures, then reliability and surface area are improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical separator placement methods with deposition techniques (chemical vapor deposition, physical vapor deposition, spin coating, or dip coating). This substitution allows the separator to be conformally deposited onto complex three-dimensional electrode structures, reducing mechanical stress and eliminating the need for precise mechanical assembly, thereby improving reliability while managing manufacturing complexity.
Solution Approach 2:
The patent changes the physical state and deposition parameters of the separator material. By controlling deposition conditions (temperature, pressure, coating speed), the separator is formed as a conformal thin film that adapts to the three-dimensional electrode geometry. This parameter control enables reliable separator integration without requiring complex mechanical assembly processes.
2Reliability
If a conformal separator is deposited on protruding electrodes, then mechanical stress is reduced and reliability improved, but manufacturing process complexity increases
Solution Approach 1:
The patent employs deposition processes that serve multiple functions simultaneously: they deposit the separator material, conformally coat the three-dimensional electrode structures, control film thickness, and reduce mechanical stress. This multi-functionality achieves reliable electrical isolation without requiring separate manufacturing steps for each function, thereby managing process complexity.
Solution Approach 2:
The patent replaces mechanical separator placement and stress management with vapor-phase or solution-phase deposition processes. These processes naturally conform to the electrode geometry and eliminate mechanical stress through controlled film formation, achieving electrical short prevention without complex mechanical assembly operations.
3Power
If three-dimensional battery architecture is used, then energy density and power density are improved, but separator integration difficulty increases
Solution Approach 1:
The patent replaces difficult mechanical separator integration in three-dimensional structures with deposition processes. Chemical vapor deposition, physical vapor deposition, spin coating, or dip coating methods allow the separator to be conformally formed around complex electrode geometries, making separator integration as easy as applying a coating rather than mechanically assembling complex components.
Solution Approach 2:
The patent controls deposition parameters (temperature, pressure, coating speed, material concentration) to optimize separator formation on three-dimensional electrodes. By adjusting these parameters, the process accommodates various electrode geometries and scales, making three-dimensional battery manufacturing feasible despite increased structural complexity.
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 enhances the surface area and reliability of three-dimensional lithium batteries by reducing mechanical stress and the probability of electrical shorts, leading to improved energy and power density, and active material utilization.
Implementation Method 1
depositing a porous dielectric material as a separator using techniques such as sub-ambient pressure/suction
Implementation Method 2
depositing a porous dielectric material as a separator using techniques such as spin-on dielectric
Implementation Method 3
depositing a porous dielectric material as a separator using techniques such as electrophoretic deposition
Implementation Method 4
depositing a porous dielectric material as a separator using techniques such as chemical vapor deposition
Implementation Method 5
A porous dielectric material may be deposited on the plurality of electrodes
Implementation Method 6
A porous dielectric material may be deposited on the plurality of electrodes
Data Source
AI summary
Methods to manufacture a three-dimensional battery are disclosed and claimed. A structural layer may be provided. A plurality of electrodes may be fabricated, each electrode protruding from the structural layer. A porous dielectric material may be deposited on the plurality of electrodes.