Energy Storage Stack Insulation and Connection Method
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Solution Overview
Problem
The existing methods for forming and processing stacks for energy storage devices, such as solid-state thin film cells, are inefficient, making commercialization difficult due to challenges in forming effective electrical connections and preventing passivation or shorts.
Innovation Solution
A method involving depositing a first insulating material over exposed portions of the electrode and electrolyte layers, followed by a conductive material to establish electrical connections between electrode layers, using techniques like inkjet printing at ambient temperatures, which allows for efficient and reliable cell production while reducing material usage and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If part of the protective layer is removed by etching or a mask is applied to expose current collector, then electrical connection can be established, but the process becomes complex and inefficient
Solution Approach 1:
The current collector is designed with an exposed portion that is pre-configured during stack formation, eliminating the need for post-assembly etching or masking operations. This preliminary exposure of the current collector surface allows direct electrical connection while simplifying the overall processing workflow.
Solution Approach 2:
The exposed portion of the current collector is extracted from the protective layer structure, creating a dedicated contact region that protrudes or is accessible without requiring removal of the protective layer. This separation of functions allows the protective layer to remain intact while providing electrical access.
2Quantity of substance
If conventional deposition methods are used, then material coverage is achieved, but deposition requires high temperature and pressure making production inefficient
Solution Approach 1:
Conventional thermal vapor deposition is replaced with inkjet printing technology, which uses mechanical ejection of liquid or aerosol material droplets. This substitution eliminates the need for high vacuum and heating systems, enabling deposition at ambient temperature and pressure while maintaining precise material placement and coverage.
Solution Approach 2:
The deposition process parameters are fundamentally changed from high temperature and vacuum conditions to ambient temperature and atmospheric pressure. The material is delivered in liquid or aerosol form through inkjet nozzles, allowing controlled deposition without thermal or vacuum processing infrastructure.
3Reliability
If expensive conductive ink is used for electrical connection, then connection reliability is improved, but production cost increases
Solution Approach 1:
The exposed portion of the current collector itself is utilized as the electrical connection medium rather than applying a separate conductive layer. By designing the current collector with an accessible surface region, the existing conductive material serves dual purposes: current collection and inter-cell electrical connection, eliminating expensive conductive ink requirements.
Solution Approach 2:
The current collector is designed to perform multiple functions: it collects current from the electrode, provides structural support, and serves as the electrical connection interface to subsequent cells. This multi-functionality eliminates the need for separate conductive connection materials, reducing overall material costs while maintaining connection reliability.
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 efficient and reliable connection of cells in parallel, reducing production costs and improving the efficiency of energy storage device manufacturing by using inexpensive anode material and minimizing material usage, while preventing shorts and ensuring accurate deposition.
Implementation Method 1
whereby the first material insulates the exposed portions of the first electrode layer and the electrolyte layer from the second material
Implementation Method 2
depositing a first material over an exposed portion of the first electrode layer and an exposed portion of the electrolyte layer
Implementation Method 3
depositing a second material over the first material and to contact the second electrode layer, to provide an electrical connection from the second electrode layer, for connecting to a further such second electrode layer via the second material
Data Source
AI summary
A method comprises obtaining a stack for an energy storage device, the stack comprising a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer. The method comprises depositing a first material over an exposed portion of the first electrode layer and an exposed portion of the electrolyte layer; and depositing a second material over the first material and to contact the second electrode layer. The second material provides an electrical connection from the second electrode layer, for connecting to a further such second electrode layer via the second material. The first material insulates the exposed portions of the first electrode layer and the electrolyte layer from the second material. Also disclosed is an apparatus.