Planar Solid State Battery Stacks for Implantable Devices
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Solution Overview
Problem
Current methods for fabricating high-density power sources from solid state planar batteries in implantable medical devices are inefficient, requiring improved stack configurations and fabrication techniques to enhance energy storage and delivery.
Innovation Solution
The method involves stacking planar solid state batteries in an aligned arrangement with conductive channels and vias to form a high-density power source, using redistribution layers to electrically connect battery contacts and provide stress relief, allowing for efficient energy storage and delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple planar solid state batteries are stacked in an aligned arrangement to form a high-density power source, then energy storage capacity increases, but manufacturing complexity and fabrication difficulty increase
Solution Approach 1:
The power source is segmented into multiple individual planar solid state batteries that are stacked in an aligned arrangement. Each battery is a separate unit with its own contacts, allowing independent fabrication and assembly while contributing to the overall energy storage capacity of the power source.
Solution Approach 2:
Multiple planar solid state batteries are nested vertically in a stacked configuration, with each battery layer containing the necessary electrical contacts and conductive pathways. This nesting approach maximizes energy density by utilizing three-dimensional space efficiently while maintaining modular construction.
2Reliability
If conductive channels and redistribution layers are added to connect battery contacts in the stack, then electrical connectivity improves, but fabrication steps and manufacturing complexity increase
Solution Approach 1:
The conductive channels and redistribution layers are merged into an integrated electrical connection system that spans multiple battery layers. This consolidation provides reliable electrical connectivity between stacked batteries while reducing the number of separate fabrication steps compared to individual connection methods.
Solution Approach 2:
Electrical connectivity is achieved by extending conductive channels and redistribution layers into the vertical dimension across multiple battery layers. This three-dimensional electrical pathway design improves connectivity reliability without requiring complex lateral routing between batteries.
3Volume of moving object
If batteries are adhered together in a compact stack configuration, then device volume decreases, but stress on individual batteries during charge/discharge cycles increases
Solution Approach 1:
The stack configuration uses composite construction with multiple planar solid state batteries adhered together in a compact arrangement. This composite structure achieves reduced power source volume while the distributed stress across multiple battery units and the adhered configuration helps manage mechanical stress during charge/discharge cycles.
Data Source
AI summary
Arrays of planar solid state batteries are stacked in an aligned arrangement for subsequent separation into individual battery stacks. Prior to stacking, a redistribution layer (RDL) is formed over a surface of each wafer that contains an array; each RDL includes first and second groups of conductive traces, each of the first extending laterally from a corresponding positive battery contact, and each of the second extending laterally from a corresponding negative battery contact. Conductive vias, formed before or after stacking, ultimately couple together corresponding contacts of aligned batteries. If before, each via extends through a corresponding battery contact of each wafer and is coupled to a corresponding conductive layer that is included in another RDL formed over an opposite surface of each wafer. If after, each via extends through corresponding aligned conductive traces and, upon separation of individual battery stacks, becomes an exposed conductive channel of a corresponding battery stack.