Conformal Solid-State Battery Structure for Higher Power Density
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Solution Overview
Problem
Conventional solid-state batteries (SSBs) face limitations in integrating solid-state electrolytes due to lower ionic conductivities, leading to poor electrode/electrolyte interface contact and restricted energy and power densities, while liquid electrolytes pose safety risks, especially in compact applications like medical implants.
Innovation Solution
A method involving electrochemical anodization and semiconductor manufacturing processes to create a high-aspect ratio structured substrate with nanopores, allowing conformal deposition of battery layers, ensuring intimate contact and high surface area, thereby enhancing energy and power densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid-state electrolytes are used to replace liquid electrolytes, then safety is improved, but ionic conductivity deteriorates
Solution Approach 1:
The patent employs porous solid electrolyte layers with controlled porosity (30-70%) to increase the effective surface area for ionic transport. The porous structure allows ions to access more electrolyte material simultaneously, effectively compensating for the lower ionic conductivity of solid materials compared to liquids, while maintaining the inherent safety advantages of solid-state electrolytes
Solution Approach 2:
The invention transitions from planar 2D electrode/electrolyte interfaces to 3D conformal interfaces by depositing layers that conformally coat the porous electrolyte structure. This dimensional transformation increases the interfacial contact area and provides multiple parallel pathways for ion transport, thereby enhancing overall ionic conductivity while maintaining safety
2Ease of manufacture
If planar cell structure is used, then manufacturing simplicity is improved, but energy density and power density deteriorate
Solution Approach 1:
The patent introduces 3D conformal structures within the planar cell architecture by creating porous electrolyte layers and conformally depositing electrode materials throughout the pore structures. This adds vertical and lateral dimensionality to the ion transport pathways, dramatically increasing power density while maintaining compatibility with existing planar manufacturing processes
Solution Approach 2:
By incorporating porous materials with high surface area-to-volume ratios, the invention enables significantly increased energy and power densities within the same planar footprint. The porous structure allows for greater amounts of active material to be packed into the same volume while maintaining efficient ion transport pathways
3Use of energy by moving object
If cathode layer thickness is increased to improve energy density, then energy capacity is improved, but power performance deteriorates due to longer ion travel distance
Solution Approach 1:
The patent applies local quality by creating non-uniform cathode layer thicknesses that are optimized for local ion transport requirements. Thinner cathode regions are positioned where rapid ion transport is needed for high power delivery, while thicker regions are placed where energy storage is prioritized. This spatial variation in layer thickness allows simultaneous optimization of both energy capacity and power performance
Solution Approach 2:
The invention transforms the single-path ion transport through thick planar cathodes into multi-dimensional transport pathways by conformally coating porous electrolyte structures. This creates numerous parallel ion transport channels that reduce the effective travel distance for ions, enabling thick cathode layers to maintain high power performance while providing increased energy capacity
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
The method produces conformal solid-state batteries with significantly higher energy and power densities, avoiding liquid electrolyte risks, and maintaining safety in compact applications.
Implementation Method 1
an electrochemical anodization process to produce nanopores within the patterned solid substrate surface
Implementation Method 2
By conformally depositing various layers within the nanopores
Data Source
AI summary
The present disclosure provides a conformal solid-state battery (SSB) and methods for producing and using the same. The SSBs produced using a method of the disclosure have a higher energy and power compared to similar solid-state batteries without conformal electric cells. Due to avoidance of using any liquid electrolytes, SSBs of the disclosure have increased safety, especially in cases of medical implants and/or during catastrophic failures, where reactions of liquid electrolytes with air and/or water can produce toxic and/or poisonous by products.