Electrochemical Device Manufacturing via Substrate Segmentation
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Solution Overview
Problem
Current methods for manufacturing electrochemical devices like batteries and supercapacitors face challenges in high-yield, low-cost mass production due to limitations in mechanical mask usage, such as high investment costs, low integration density, and particulate contamination, which can lead to defects and reduced production rates, especially when producing devices of different sizes and shapes.
Innovation Solution
A method involving the formation of multiple elementary entities on a substrate, each comprising a current collector, electrode, and ionically conductive layer, followed by cutting and electrical connection in parallel to create electrochemical devices of varying sizes and shapes, eliminating the need for specific masks and reducing the impact of defects, thereby increasing production efficiency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical masks are used for successive depositions of active layers, then the desired shape can be obtained, but the investment cost increases and production rate decreases
Solution Approach 1:
The substrate is divided into multiple elementary entities (at least two) that are formed simultaneously through blanket deposition. Each elementary entity comprises complete active layers (electrodes, electrolyte, current collectors), and these entities are later separated by cutting. This segmentation approach eliminates the need for mechanical masks during deposition, thereby increasing production rate while maintaining shape definition through post-deposition cutting.
2Manufacturing precision
If mechanical masks are used for successive depositions, then shape control is achieved, but manufacturing cost increases due to mask manufacture, alignment and cleaning
Solution Approach 1:
The masking step is extracted and removed from the deposition process. Instead of using mechanical masks to define shapes during deposition, the invention forms complete layers over the entire substrate and then separates the elementary entities through cutting. This extraction eliminates all costs associated with mask manufacture, alignment, and cleaning.
Solution Approach 2:
The active layers are deposited in advance over the entire substrate surface in a blanket deposition mode, forming complete elementary entities before any separation or shaping operations. This preliminary action allows the use of simple, low-cost deposition techniques without requiring expensive precision masks.
3Manufacturing precision
If mechanical masks are used, then deposition areas are defined, but particulate contamination occurs leading to yield loss
Solution Approach 1:
The mechanical mask component is completely removed from the system. By replacing mask-based deposition area definition with blanket deposition followed by cutting, the source of particulate contamination is eliminated, thereby preventing yield loss from defective products.
4Productivity
If blanket deposition is used without masks, then production rate increases, but continuity defects can affect all microbatteries
Solution Approach 1:
The substrate is segmented into multiple independent elementary entities, each containing complete active layers. This segmentation creates isolation barriers that prevent defect propagation between entities. When a continuity defect occurs during blanket deposition, it is confined to specific elementary entities rather than affecting the entire substrate, thereby maintaining reliability while allowing high-rate blanket deposition.
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 enables high-yield, low-cost mass production of electrochemical devices with improved yield and reduced manufacturing costs by allowing for the production of devices with different sizes and shapes from the same substrate, minimizing the impact of defects and optimizing the use of substrate space.
Implementation Method 1
The migration of one or more ions between the two electrodes 3, 5 through the electrolyte makes it possible to store energy or to deliver it
Implementation Method 2
the most widespread method, for example described in document US 6,764,525, consists in carrying out successive depositions of active layers
Data Source
Figure 1~2g
Figure 3a~4d
Figure 5a~5d
AI summary
A method for manufacturing at least the first and second electrochemical devices, such as electrochromic systems or systems for energy storage, for example microbatteries, batteries or supercapacitors, comprising the following successive steps: a) providing a substrate (1) comprising a first group of whole elementary entities (8), each whole elementary entity (8) comprising: - a first current collector (4), of a first polarity, - a first electrode (3), - an ionically conductive and electrically insulating thin film (7), - a second electrode (5), - a second current collector (6), of a second polarity, b) cutting the substrate (1) so as to form at least second and third groups of elementary entities (8, 9) each comprising a plurality of whole elementary entities (8) from the first group of whole elementary entities (8),the partitioning being carried out so as to form a plurality of non-integer elementary entities (9) in each of the second and third groups of elementary entities (8, 9), all or part of the elementary entities (8, 9) arranged at the periphery of the second group of elementary entities (8, 9) and/or the third group of elementary entities (8, 9) being non-integer elementary entities (9), c) electrically connect in parallel the current collectors (4, 6) of the same polarity of the integer elementary entities (8) of the second group of elementary entities without electrically connecting the non-integer elementary entities (9) to form the first electrochemical device, d) electrically connect in parallel the current collectors (4, 6) of the same polarity of the integer elementary entities (8) of the third group of elementary entities without electrically connecting the non-integer elementary entities (9) to form the second electrochemical device.