Embedded Solid-State Battery Roll-to-Roll Deposition
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Solution Overview
Problem
Conventional methods for manufacturing solid-state thin film batteries face challenges such as handling issues with brittle cathode and electrolyte layers, limited scalability, and poor termination techniques leading to parasitic losses and reduced energy density, making it difficult to produce robust and efficient batteries for consumer electronics and automotive applications.
Innovation Solution
A process for manufacturing solid-state thin film batteries using a complete deposition of all electrochemical cell materials, including anode, cathode, electrolyte, barriers, and embedded current collectors, in a roll-to-roll continuous process, allowing for the formation of robust products with minimal handling and particulate issues, and enabling the optimization of energy density and yield by utilizing extremely thin layers and strategic placement of smoothing and insulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional handling methods are used for brittle cathode and electrolyte layers, then manufacturing process is simple, but layer damage and particulate issues increase reducing yield
Solution Approach 1:
The patent combines multiple thin layers (cathode, electrolyte, current collectors) into a single integrated structure deposited on a continuous substrate. This merging eliminates the need for separate handling of brittle layers, as they are formed together in a continuous process, thereby maintaining layer integrity while simplifying manufacturing.
Solution Approach 2:
The patent performs preliminary deposition of all layers onto a continuous substrate before any cutting or separation operations. This preliminary action ensures that layers are formed in their final configuration while still supported by the substrate, preventing damage that would occur if layers were handled separately after formation.
2Loss of energy
If individual layers are handled separately during manufacturing, then process flexibility is high, but parasitic losses and energy density decrease
Solution Approach 1:
The patent merges all electrochemical layers into a single continuous structure deposited on one substrate. This eliminates the need for multiple handling operations between layers, reducing parasitic losses from exposure to air and contaminants, while the overall process remains manageable through continuous deposition techniques.
Solution Approach 2:
The patent employs deposition processes that create layers in a controlled environment, minimizing exposure to ambient conditions that cause parasitic reactions. The continuous substrate provides protection during manufacturing, effectively creating an inert environment that reduces energy losses.
3Quantity of substance
If thick layers are used to ensure robustness, then mechanical strength is improved, but energy density decreases
Solution Approach 1:
The patent utilizes thin film deposition techniques to create sufficiently robust layers at minimal thickness. The continuous substrate provides mechanical support, allowing the electrochemical layers to be made extremely thin while maintaining overall structural integrity, thereby maximizing energy density without sacrificing necessary robustness.
4Reliability
If current collectors are terminated with physical contact, then electrical connection is reliable, but damage risk and yield reduction increase
Solution Approach 1:
The patent introduces a smoothing and insulating layer as an intermediary between the brittle electrochemical layers and the current collectors. This intermediary layer provides mechanical protection during termination operations, allowing reliable electrical connections to be made without directly contacting and potentially damaging the underlying electrochemical layers, thereby maintaining yield.
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 the production of high-energy density batteries with reduced parasitic volume and mass, improved yield, and enhanced robustness, allowing for the manufacture of large numbers of stacked battery cells without layer handling, and optimizing energy density and mass in compact devices.
Implementation Method 1
a process for complete deposition of all electrochemical cell materials
Data Source
AI summary
Elements of an electrochemical cell using an end to end process. The method includes depositing a planarization layer, which manufactures embedded conductors of said cell, allowing a deposited termination of optimized electrical performance and energy density. The present invention covers the technique of embedding the conductors and active layers in a planarized matrix of PML or other material, cutting them into discrete batteries, etching the planarization material to expose the current collectors and terminating them in a post vacuum deposition step.