Laser Shaping Thin Film Battery Structures
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Solution Overview
Problem
Conventional thin film battery fabrication methods face challenges in achieving high energy density and specific energy levels due to the limitations of substrates and the use of masking processes, which can lead to non-uniform or broken edges and increased contamination and stress fractures.
Innovation Solution
The use of a pulsed laser ablation process to shape battery component films on a substrate without masks, allowing for the formation of three-dimensional structures with reduced delamination and micro-crack formation, while utilizing crystalline substrates like mica for enhanced mechanical strength and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional masking and deposition processes are used to shape battery component films, then three-dimensional battery structures can be formed, but non-uniform or broken edges occur and contamination and stress fractures increase
Solution Approach 1:
The patent replaces the mechanical masking system with a direct laser writing system. Instead of using physical masks that cause edge damage when peeled off, the invention uses a laser to directly write and define the three-dimensional battery structure on the substrate, eliminating mask-related contamination and edge defects
Solution Approach 2:
The invention extracts and removes the masking step from the fabrication process entirely. By using direct laser writing, the patent eliminates the mask layer and its associated problems (contamination, edge sticking, fracture), achieving shape definition through laser ablation and deposition without any intermediate masking material
2Shape
If multiple masking and deposition steps are used to form three-dimensional structures, then battery features can be shaped, but process complexity and handling steps increase
Solution Approach 1:
The patent merges multiple separate masking and deposition operations into a single integrated direct laser writing process. The laser system performs both the shaping and structuring operations in one continuous process, eliminating the need for multiple discrete handling steps and reducing overall process complexity
Solution Approach 2:
The invention extracts and eliminates the masking step from the multi-step fabrication process. By using direct laser writing, complex three-dimensional structures are formed through a single streamlined process rather than through multiple sequential masking and deposition cycles
3Strength
If conventional substrates are used to provide mechanical support, then adequate structural integrity is achieved, but substrate thickness increases and energy density decreases
Solution Approach 1:
The patent changes the substrate parameter from conventional thick substrates to ultra-thin substrates with thicknesses less than 100 microns. This parameter change enables reduced substrate volume while maintaining structural integrity through the direct laser writing process that creates optimized three-dimensional battery structures
4Ease of manufacture
If mask edges stick to the substrate during peeling, then mask removal is attempted, but portions of plate-like layers are removed and edges become non-uniform or broken
Solution Approach 1:
The invention extracts and eliminates the mask from the fabrication process entirely. By using direct laser writing, there is no mask to remove, thus completely avoiding the problem of mask edges sticking to the substrate and causing edge damage or non-uniform features
Solution Approach 2:
The patent replaces the mechanical mask-based shaping system with a laser-based direct writing system. This substitution eliminates the physical mask material that causes adhesion and edge damage problems, using laser energy instead to define features without any contact or removal 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 enables the creation of thin film batteries with improved energy density and specific energy levels, reduced contamination, and increased process throughput by avoiding mask-related issues and minimizing handling steps, resulting in more efficient and reliable battery fabrication.
Implementation Method 1
A pulsed laser beam bursts vaporize portions of the deposited films with reduced delamination or micro-crack formation, especially when the films are shaped over a substrate having cleavage planes
Data Source
AI summary
A method of fabricating a battery comprises selecting a battery substrate having cleavage planes, and depositing on the battery substrate, one or more battery component films comprising electrode films that at least partially surround an electrolyte film. Pulsed laser beam bursts are applied to the battery component films at a sufficiently high power level to vaporize portions of the films to form shaped battery features. The pulsed laser bursts shape the films substantially without causing fractures along the cleavage planes of the battery substrate. Pulsed laser shaping can be used to replace the use of a mask in the fabrication of shaped battery components.