3D Folded Battery Stack With Interdigitated Thin-Film Electrodes
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Solution Overview
Problem
Current battery technologies face challenges in efficiently manufacturing three-dimensional folded battery units with interdigitated anode and cathode stacks that can be easily integrated into various battery housing geometries, while maintaining electrical integrity and ion transport efficiency.
Innovation Solution
A method involving the fabrication of anode and cathode assemblies with conductive materials, interconnects, and separators, which are then folded to form boustrophedonic stacks within a battery housing, utilizing techniques like die-cutting, spray-coating, and vapor deposition to create thin-film electrodes and separators that prevent shorting and facilitate ion transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional battery manufacturing methods are used, then manufacturing process is simple, but manufacturing precision and electrical integrity are insufficient
Solution Approach 1:
The battery structure is segmented into multiple thin-film layers (anode, cathode, separators, interconnects) that are individually manufactured with high precision using vapor deposition and spray-coating, then assembled through controlled folding. This segmentation allows each layer to be optimized independently for electrical integrity while maintaining manufacturing feasibility through modular processing steps.
Solution Approach 2:
The patent transitions from traditional two-dimensional planar battery structures to three-dimensional folded configurations. By folding thin-film layers into vertical stacks with interdigitated anode and cathode columns, the design achieves higher manufacturing precision for electrical connections while accommodating complex manufacturing processes through automated folding and stacking operations.
2Productivity
If three-dimensional folded structure is implemented, then battery efficiency and compactness improve, but manufacturing difficulty increases
Solution Approach 1:
Electrode layers, separators, and interconnects are pre-manufactured as thin-film structures with precise material deposition before assembly. The vapor deposition and spray-coating processes create pre-formed layers that are then folded and stacked, allowing high battery efficiency to be achieved while managing manufacturing complexity through preparatory fabrication steps.
Solution Approach 2:
Traditional mechanical assembly methods are replaced with vapor deposition and spray-coating techniques to create thin-film layers. These deposition processes enable precise material placement and bonding without complex mechanical fastening, achieving high battery efficiency through superior material integration while simplifying the overall manufacturing approach.
3Productivity
If thin-film electrodes and separators are used, then ion transport efficiency improves, but risk of shorting increases
Solution Approach 1:
Separator layers are introduced as intermediary structures between anode and cathode thin-film electrodes. These separators provide physical isolation that prevents shorting while maintaining ion transport pathways, allowing the use of ultra-thin electrodes for high ion transport efficiency without compromising reliability. The separators act as mediating elements that enable both performance and safety.
Solution Approach 2:
The patent employs flexible thin-film separators that conform to the folded battery structure. These thin-film separators maintain close proximity to the electrodes for efficient ion transport while providing sufficient insulation to prevent shorting. The flexibility of the thin-film structure allows it to accommodate the three-dimensional folded geometry while maintaining both ion transport efficiency and shorting prevention.
4Reliability
If boustrophedonic stacking is used, then electrical connections are optimized, but structural complexity increases
Solution Approach 1:
The battery is segmented into discrete columns with alternating anode and cathode arrangements in a boustrophedonic pattern. This segmentation creates modular units that are easier to manufacture and assemble, with each column forming a complete electrochemical cell. The segmented structure optimizes electrical connections between columns while managing overall structural complexity through repetitive modular design.
Solution Approach 2:
The boustrophedonic stacking creates a curved, folded three-dimensional structure rather than a flat planar arrangement. This curvature optimizes electrical connections by bringing electrode surfaces into closer proximity and creating efficient current pathways through the folded layers. The curved geometry manages structural complexity by distributing connections across multiple folded planes rather than requiring complex three-dimensional wiring.
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 creation of compact, efficient battery units that can be tailored to fit different battery housing geometries, ensuring reliable electrical connections and ion transport, thereby enhancing the performance and versatility of battery designs.
Implementation Method 1
utilizing techniques like die-cutting, spray-coating, and vapor deposition to create thin-film electrodes and separators
Implementation Method 2
utilizing techniques like die-cutting, spray-coating, and vapor deposition to create thin-film electrodes and separators
Data Source
AI summary
One variation of a battery unit includes: a series of anode collectors; a set of anode electrodes including anode material arranged on both side of the anode collectors; a set of anode interconnects interposed between and electrically coupling adjacent anode collectors and folded to locate the anode collectors in a boustrophedonic anode stack; a series of cathode collectors; a set of cathode electrodes including cathode material arranged on both side of the cathode collectors; a set of cathode interconnects interposed between and electrically coupling adjacent cathode collectors and folded to locate the cathode collectors in a boustrophedonic cathode stack with cathode collectors interdigitated between anode collectors in the boustrophedonic anode stack; and a set of separators arranged between the anode and cathode electrodes and transporting solvated ions between the anode and cathode electrodes.