Electrophoretic Deposition for 3D Thin-Film Battery Stacks
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Solution Overview
Problem
Existing methods face challenges in forming solid separators for three-dimensional thin-film batteries using wet chemistry and struggle to electrochemically deposit full three-layer battery stacks, especially with glass-ceramic layers inside through-holes or on planar substrates, and require two current collectors for electrophoretic deposition of mutually repulsive electrodes.
Innovation Solution
The development of electrophoretic deposition (EPD) methods to produce partial or full thin-film battery stacks on both planar and 3D substrates using a single electronically conductive substrate, where layers are deposited in sequence, including a porous inorganic solid separator that provides pathways for cations, allowing for the deposition of three-layer stacks on a single current collector, and the use of ion-conductive liquids to enhance ionic conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet chemistry methods are used to form separators, then separator formation is achieved, but the process is complex and difficult to apply to three-dimensional structures
Solution Approach 1:
The patent replaces wet chemistry methods with electrophoretic deposition (EPD) to form separators. EPD uses an electric field to deposit charged particles from a suspension onto a substrate, eliminating the need for complex wet chemistry processes while enabling formation of separators on three-dimensional structures including inside through-holes.
Solution Approach 2:
The patent changes the deposition mechanism from chemical to electrokinetic by applying an electric field. By controlling parameters such as voltage, suspension composition, and deposition time, the process achieves simple and controllable separator formation with reduced process complexity.
2Productivity
If electrophoretic deposition is used to deposit battery layers, then layer deposition is achieved, but the deposited layers are porous rather than dense
Solution Approach 1:
The patent accepts and utilizes the porous nature of EPD-deposited layers rather than attempting to eliminate porosity. The porous structure provides benefits for ion transport in battery applications. The process achieves efficient deposition of functional battery layers with appropriate porosity for electrochemical performance.
3Ease of operation
If two current collectors are used for electrophoretic deposition of mutually repulsive electrodes, then electrode deposition is achieved, but the device complexity increases
Solution Approach 1:
The patent makes the separator layer multi-functional by enabling it to serve as both a physical separator and an electrophoretic deposition substrate. The separator is deposited first with appropriate surface charge, then subsequent electrodes are deposited on it. This eliminates the need for two current collectors while maintaining the ability to deposit mutually repulsive electrodes by controlling the charge of each layer.
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 successful formation of conformal thin-film battery stacks in both 2D and 3D configurations with improved ionic conductivity and reduced porosity, achieving stable and efficient energy storage performance, including the ability to form concentric microbatteries entirely by EPD, with enhanced power and energy density per footprint.
Implementation Method 1
Electrophoresis refers to the motion of charged particles in a liquid under an applied electric field. Electrophoresis can be used to deposit materials in the form of thin films (layers), coatings and bulk products.
Implementation Method 2
The deposition process is commonly termed electrophoretic deposition (EPD).
Implementation Method 3
separated by an ionically conducting and electronically insulating (non-conducting) separator layer
Data Source
AI summary
Methods for forming three-layer thin-film battery (TFB) structures by sequential electrophoretic deposition (EPD) on a single conductive substrate. The TFBs may be two-dimensional or three-dimensional. The sequential EPD includes EPD of a first battery electrode followed by EPD of a porous separator on the first electrode and by EPD of a second battery electrode on the porous separator. In some embodiments of a Li or Li-ion TFB, the separator includes a Li ion conducting solid. In some embodiments of a Li or Li-ion TFB, the separator includes an inorganic porous solid rendered ionically conductive by impregnation with a liquid or polymer. In some embodiments, the TFBs are coated and sealed with an EPDd PEEK layer.