Ceramic Micro-Bonded Microbattery Casing for Thin Hermetic Sealing
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Solution Overview
Problem
Current miniature electrochemical cells face limitations in energy density and shape flexibility due to non-porous electrodes, solid-state diffusion constraints, and the need for precision machining, which restricts their capacity and applicability in medical devices.
Innovation Solution
The development of a miniature electrical energy power source using micro-bonded optically transparent ceramic wafers with conductive pathways and thin-film current collectors, allowing for a hermetic and flexible casing design with reduced wall thickness and increased capacity, enabling the creation of power sources with capacities greater than 4000 μAh/cm² in various shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass-to-metal seal is used in cylindrical cell design, then hermetic sealing is achieved, but casing wall thickness increases to about 625 μm reducing available electrode area
Solution Approach 1:
The patent changes the sealing material from glass-to-metal to ceramic-to-ceramic bonding, and changes the cell shape from cylindrical to planar. This allows achieving hermetic sealing with a much thinner casing wall of about 100 μm, increasing the electrode area by a factor of 6.25 compared to the cylindrical design.
Solution Approach 2:
The patent transitions from a cylindrical (curved) cell design to a planar (flat) cell design. This geometric change eliminates the need for thick circumferential sealing walls, allowing the casing wall thickness to be reduced from 625 μm to 100 μm while maintaining hermetic sealing through ceramic-to-ceramic bonding.
2Ease of manufacture
If non-porous electrodes are used with solid-state diffusion, then manufacturing is simplified, but reaction rate and capacity are limited to about 75-100 μAh/cm²
Solution Approach 1:
The patent changes the electrode structure from non-porous to porous, enabling liquid electrolyte penetration and significantly increasing the reaction rate. This allows the cell to achieve capacities greater than 4000 μAh/cm², a 40-50 times increase over solid-state diffusion limited cells, while maintaining manufacturing feasibility through automated assembly.
3Reliability
If precision machining and assembly of individual parts is used, then cell assembly is achieved, but manufacturing complexity and time increase for high-volume production
Solution Approach 1:
The patent segments the cell into standardized planar components (casing, electrodes, separator) that can be manufactured independently and assembled automatically. This modular approach maintains assembly precision while enabling high-volume production through automated pick-and-place techniques, significantly increasing manufacturing speed compared to precision machining of individual parts.
Solution Approach 2:
The patent replaces precision mechanical machining and assembly with automated assembly processes that position pre-fabricated components. This substitution maintains the precision required for reliable cell assembly while dramatically increasing manufacturing throughput for high-volume production.
4Reliability
If cylindrical cell shape is used with glass-to-metal seal, then hermetic sealing is reliable, but shape flexibility is restricted
Solution Approach 1:
The patent adopts a planar (flat) cell geometry instead of cylindrical, which inherently provides greater shape flexibility. Combined with ceramic-to-ceramic bonding technology, this planar design maintains hermetic sealing reliability while allowing the cell to be integrated into various device configurations and orientations.
Solution Approach 2:
The patent changes the sealing interface from glass-to-metal (cylindrical) to ceramic-to-ceramic (planar), which enables flexible shaping of the cell. The ceramic material and bonding method allow the cell to be manufactured in various shapes and sizes, improving adaptability to different medical device applications while maintaining sealing reliability.
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 results in a compact, high-capacity power source with a delivered capacity of about 300 μAh, enabling efficient energy storage for medical devices while minimizing casing wall thickness and allowing for non-cylindrical designs.
Implementation Method 1
a laser light directed at the transparent cover glass then penetrates through the cover glass to heat and melt a portion of the second transparent ceramic sheet at the interface
Implementation Method 2
heat and melt a portion of the second transparent ceramic sheet at the interface between the first and second transparent ceramic sheets to cause interdiffusion of the ceramic materials
Implementation Method 3
The electrical energy power source comprises an electrode assembly housed inside the casing
Data Source
AI summary
An electrical energy power source comprises a casing made by micro-bonding an upper ceramic wafer and a lower ceramic wafer to the opposed surfaces of a ceramic ring. The upper and lower ceramic wafers have respective first and second conductive pathways extends therethrough. A first current collector supporting a first active material layer contacts the upper ceramic wafer and the first conductive pathway, and a second current collector supporting a second, opposite polarity active material layer contacts the lower ceramic wafer and the second conductive pathway. A separator resides between the first and second active materials, and an electrolyte filled into the casing through a fill port activates the active materials. The first and second conductive pathways serve as opposite polarity terminals for the power source.