Double-Sided Energy Storage Groove Layout for Higher Energy Density
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Solution Overview
Problem
Current methods for manufacturing energy storage devices are inefficient and complex, particularly in forming grooves on double-sided structures, which can lead to interference and reduced energy density due to the need for multiple directional processing.
Innovation Solution
A method involving a substrate with a first stack and a second stack on opposite sides, where grooves are formed on one side to allow for mirrored processing from a single direction, increasing energy density by optimizing the ratio of active material to substrate and reducing material removal, and using laser ablation for precise groove formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If grooves are formed on both sides of the substrate to create double-sided energy storage structure, then energy density is improved, but manufacturing complexity increases due to interference between opposite sides
Solution Approach 1:
The patent applies inversion by forming grooves on both sides of the substrate simultaneously from opposite directions. Instead of processing one side at a time sequentially, the method inverts the approach by using dual-sided concurrent processing, where grooves are formed from both the first side and second side of the substrate at the same time, eliminating interference and simplifying manufacturing.
Solution Approach 2:
The patent transitions from single-sided to double-sided processing by adding a spatial dimension. By utilizing both sides of the substrate for groove formation, the manufacturing process moves from a one-dimensional (single direction) approach to a two-dimensional (dual direction) approach, effectively doubling the energy storage capacity without proportionally increasing manufacturing complexity.
2Manufacturing precision
If multiple directional processing is used to form grooves on double-sided structures, then complete groove formation is achieved, but processing time and efficiency increase
Solution Approach 1:
The patent merges the groove formation operations for both sides of the substrate into a single simultaneous process. By combining the processing operations that would otherwise be performed separately and sequentially, the method achieves complete groove formation on both sides while reducing total processing time and improving manufacturing efficiency.
Solution Approach 2:
The patent implements continuous useful action by performing groove formation on both sides of the substrate concurrently without interruption. The dual-sided processing allows both grooves to be formed in a continuous operation rather than stopping to process one side, then the other, thereby eliminating idle time and maximizing productivity.
3Quantity of substance
If grooves are formed deeper to increase active material exposure, then energy storage capacity improves, but risk of short circuits increases
Solution Approach 1:
The patent applies local quality by forming grooves of different depths at different locations on the substrate. By varying the groove depth locally rather than uniformly, the method optimizes active material exposure in specific areas while maintaining adequate insulation in other areas, thereby increasing energy storage capacity without proportionally increasing short circuit risk.
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 method simplifies the formation of grooves in double-sided structures, increases energy density, and reduces the risk of short circuits by aligning grooves for efficient cutting and material deposition, enabling a scalable and efficient continuous manufacturing process.
Implementation Method 1
forming a first groove in a first side of the first stack... forming a second groove in a first side of the second stack... forming a third groove in the first side of the first stack... forming a fourth groove in the first side of the second stack
Data Source
AI summary
Methods for manufacturing an energy storage device. Such methods comprise providing a first stack on a first side of a substrate and a second stack on a second side of the substrate, opposite to the first side of the substrate. In examples, a first and third groove are formed in the first stack, with different depths than each other, and a second and fourth groove are formed in the second stack, with different depths than each other. In other examples, a first groove is formed in the first stack and a second groove is formed in the second stack, in substantial alignment with the first groove but with a different depth than the first groove.