Miniaturized Electrochemical Cell Manufacturing via Sacrificial Templates

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Solution Overview

Problem

Existing methods for manufacturing miniaturized electrochemical cells are limited by the maximum inter-electrode distance of 100 μm, which restricts the volume of solution that can be stored between electrodes and require both electrodes to be made of macroporous materials, hindering further miniaturization.

Innovation Solution

A method involving coaxial electrodes with independently prepared inner and outer electrodes, using a sacrificial hollow support and colloidal templates for electroless and electro-deposition processes to achieve tunable inter-electrode distances and allow for macroporous or non-macroporous inner electrodes, enabling larger inter-electrode gaps and flexible material choices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a single colloidal template is used to manufacture miniaturized electrochemical cells with macroporous electrodes, then the surface area of electrodes is increased, but the inter-electrode distance is limited to maximum 100 μm

Engineering Contradiction:

Improveelectrode surface areaVSAvoidinter-electrode distance

Core Design Contradiction:

Area of stationary objectVSLength of stationary object

Solution Approach 1:

The invention divides the manufacturing process into separate stages: first forming the outer electrode using a colloidal template, then removing the template and forming the inner electrode independently. This segmentation allows each electrode to be optimized separately and enables inter-electrode distances exceeding 100 μm without compromising electrode surface area.

Inventive Principle:

Principle #1Segmentation

2Productivity

If both electrodes are made of macroporous material to increase surface area, then electrochemical reaction efficiency is improved, but manufacturing flexibility is reduced

Engineering Contradiction:

Improveelectrochemical reaction efficiencyVSAvoidmaterial selection flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The invention applies different material properties to different electrodes based on their specific functional requirements. The outer electrode can be macroporous for high surface area needs, while the inner electrode can be non-macroporous if compactness or specific conductivity is prioritized. This local quality approach maintains manufacturing flexibility and enables diverse material selections for each electrode position.

Inventive Principle:

Principle #3Local quality

3Volume of stationary object

If hundreds of colloidal particle layers are used to increase inter-electrode distance, then the volume of solution storage is increased, but the manufacturing complexity and time increase significantly

Engineering Contradiction:

Improvesolution storage volumeVSAvoidmanufacturing process complexity

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

The invention performs preliminary actions by first forming the outer electrode and completely removing its colloidal template before forming the inner electrode. This preliminary removal creates sufficient space for larger inter-electrode distances without requiring multiple layers of colloidal particles, thereby simplifying the manufacturing process and reducing production time while maintaining increased solution storage volume.

Inventive Principle:

Principle #10Preliminary action

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 allows for miniaturized electrochemical cells with inter-electrode distances greater than 100 μm, enabling increased solution volume and flexibility in electrode material selection, enhancing the efficiency and miniaturization potential of electrochemical cells.

Implementation Method 1

depositing on the external surface of this support a sacrificial layer of an electrically conducting material M2, by an electroless deposition method

Methodology Applied

Scientific EffectElectroless deposition:

Implementation Method 2

depositing a sacrificial layer of an electrically conducting material M4 on the layer of electrically conducting material M2, through the template by an electro-deposition method

Methodology Applied

Scientific EffectElectro-deposition: Electrodeposition

Implementation Method 3

depositing a layer L1 of an electron conducting or semi-conducting material M5 on the layer of electrically conducting material M4 by an electro-deposition method, through the template

Methodology Applied

Scientific EffectElectro-deposition: Electrodeposition

Data Source

PatentUS10608238B2Method for manufacturing a miniaturized electrochemical cell and a miniaturized electrochemical cell

Publication Date: 2020.03.31 CENT NAT DE LA RECH SCI (C N R S)

AI summary

A miniaturized electrochemical cell and a method for making it are provided. The method includes preparing at least one inner electrode of an electron conducting or semi-conducting material M1; providing a hollow support made of an electrically insulating material M6 and having at least one internal hollow channel; depositing on the external surface of the support a layer of an electrically conducting material M2; forming a template of colloidal particles of an electrically insulating material M3, on the M2 layer; depositing a layer of an electrically conducting material M4 on the M2 layer; depositing a layer L1 of an electron conducting or semi-conducting material M5 on the M4 layer, introducing the at least one inner electrode into the at least one internal hollow channel of the obtained structure; stabilizing the structure at its two open ends with an electrically insulating material M7; and removing M2, M3, M4 and M6 materials.