Laser-Patterned Solid-State Battery ACC for Dry High-Fidelity Cells
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Solution Overview
Problem
Existing methods for forming anode current collectors (ACC) in solid-state batteries, such as photolithography and shadow masking, face challenges like wet processing, material impact on cathode and electrolyte films, and poor pattern fidelity due to mask misalignment.
Innovation Solution
Laser patterning and laser ablation are used to create high-fidelity, dry-patterned ACCs without the need for physical masks, offering flexibility, lower costs, and higher throughput by directly patterning the ACC material on the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography and etching are used to pattern the ACC, then the ACC pattern can be formed, but wet processing is required which impacts the cathode and solid-state electrolyte films
Solution Approach 1:
The patent replaces the chemical wet processing system with a laser-based system. The laser beam directly ablates or patterns the ACC material without requiring liquid chemicals, thereby eliminating the harmful wet processing effects on the cathode and electrolyte films while maintaining precise pattern formation capability
Solution Approach 2:
The patent changes the processing parameter from chemical (wet etching) to optical/thermal (laser). By using laser energy with controlled wavelength, pulse duration, and power density, the ACC is patterned through thermal ablation or direct laser writing, achieving the same patterning function without the harmful chemical byproducts and contamination associated with wet processing
2Manufacturing precision
If shadow mask is used to deposit ACC, then the ACC pattern can be formed directly, but the mask may not be in good contact with the device surface causing ACC deposition to creep under the mask opening edges
Solution Approach 1:
The patent removes the shadow mask component entirely from the system. Instead of using a physical mask that requires stable contact with the substrate, the ACC pattern is formed directly by laser writing or laser ablation of a blanket-deposited ACC layer. This eliminates the contact stability issue while maintaining pattern fidelity through digital control of the laser beam path and parameters
Solution Approach 2:
The patent uses digital patterning where the desired ACC pattern is defined by computer-controlled laser paths rather than a physical mask. The laser beam is directed to trace the exact pattern coordinates, creating a digital copy of the desired geometry without requiring physical mask fabrication, alignment, or contact stability
3Manufacturing precision
If multiple steps are used for photolithography patterning, then the ACC pattern can be formed, but the process complexity and time increase
Solution Approach 1:
The patent combines multiple patterning steps into a single laser processing operation. Instead of sequential photolithography steps (coating, pre-bake, exposure, post-bake, development, etching), the laser directly patterns the ACC in one step by writing the pattern with the laser beam or by selective ablation, dramatically reducing process complexity and increasing throughput while maintaining pattern precision
Solution Approach 2:
The patent performs preliminary blanket deposition of the ACC material across the entire substrate before patterning. This allows the subsequent laser patterning to work on a uniform, pre-formed layer, simplifying the patterning process and enabling direct writing without the need for complex mask alignment and multiple deposition steps
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 results in sharper edges, better electrical properties, and higher purity of the ACC, while avoiding wet processing and mask-related issues, enhancing the manufacturing efficiency and quality of solid-state batteries.
Implementation Method 1
laser-patterning the ACC material to define the solid-state battery cells and form an ACC in each of the cells
Data Source
AI summary
A method of making a lithium metal oxide film is disclosed. The method includes blanket-depositing a cathode material, a solid-state electrolyte, and an anode current collector (ACC) material on a substrate, laser-patterning the ACC material to define the solid-state battery cells and form an ACC in each of the cells, and cutting or dicing the solid-state battery cells through the electrolyte and the cathode material to form a cathode in each of the solid-state battery cells. The method avoids issues related to topography and wet patterning when making the cathode, electrolyte and ACC layers. The method also avoids the need to fabricate a physical mask, thereby enabling greater patterning flexibility, higher throughput and lower costs than photolithography.