Sealed Solid-State Battery Flip-Chip Mounting
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Solution Overview
Problem
Conventional electrochemical batteries face challenges in being integrated into devices that require high-temperature processing or harsh solvent handling, limiting substrate material selection and fabrication flexibility, especially when combined with other electronics in a shared substrate.
Innovation Solution
A sealed solid-state battery design featuring a stacked structure of cathode, electrolyte, and anode layers encapsulated with a polymeric sealant and a moisture barrier, allowing flip-chip mounting onto separate substrates, enabling independent fabrication of batteries and other electronics without temperature or solvent constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional electrochemical batteries are integrated into devices requiring high-temperature processing or harsh solvent handling, then the battery can be combined with other electronics in a shared substrate, but the substrate material selection and fabrication flexibility are limited
Solution Approach 1:
The battery is fabricated as a separate, self-contained module on its own substrate, then mounted as a complete unit onto the device substrate. This segmentation allows the battery to be manufactured independently without constraining the device fabrication process, resolving the contradiction between adaptability and ease of manufacture.
Solution Approach 2:
The battery is pre-fabricated on a separate substrate before being integrated into the final device. This preliminary action allows the battery substrate to be optimized for battery fabrication while the device substrate can be optimized for electronics, eliminating cross-contamination of fabrication constraints.
2Device complexity
If conventional batteries are combined with other electronics on a shared substrate, then integration is achieved, but temperature and solvent constraints limit fabrication options
Solution Approach 1:
The battery is segmented from the electronics onto a separate substrate, allowing each component to be fabricated with optimal processes without compromising integration. The battery module is then mounted as a complete unit, achieving functional integration while maintaining fabrication freedom.
Solution Approach 2:
A separate battery substrate acts as an intermediary between the battery components and the device substrate. This intermediary allows the battery to be integrated into the device while protecting the device fabrication process from temperature and solvent constraints.
3Reliability
If a sealed structure is added to protect the battery from moisture, then moisture resistance is improved, but device complexity increases
Solution Approach 1:
The sealing function is merged with the battery substrate itself, which serves both as the structural base for the battery and as the moisture barrier. This integration of multiple functions into a single component achieves moisture protection without adding structural complexity.
Solution Approach 2:
The battery substrate is designed to perform multiple functions: supporting the battery layers, providing electrical connections, and acting as a moisture barrier. This multi-functionality achieves reliability without increasing device complexity.
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 design enhances fabrication efficiency, reduces costs, and provides a compact, moisture-resistant battery suitable for biological environments, such as in body-mountable devices, with improved design flexibility and power delivery capabilities.
Implementation Method 1
A polymeric sealant material can be applied over and around the battery stack and a moisture barrier can be formed over the sealant material to thereby prevent moisture from reaching the battery
Implementation Method 2
Lithium ions are transferred through the electrolyte from the anode to the cathode to balance the flow of electrons in the circuit
Implementation Method 3
During discharge, when the battery is providing current to a circuit connected across the electrodes, redox reactions occur at the two electrodes. Oxidation reactions at the anode ionize lithium, which releases electrons to the connected circuit from the anode
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
An electrochemical battery can include electrodes (a cathode and an electrode) arranged on respective surfaces of an electrolyte. The electrodes and electrolyte can each be solid state films that can be layered on top of one another to create a stacked structure disposed on a substrate. A polymeric sealant material can be applied over and around the battery stack and a moisture barrier can be formed over the sealant material to thereby prevent moisture from reaching the battery. Conductive terminals electrically coupled to the cathode and anode, respectively, can be formed on a second side of the substrate. As such, the battery can be flip-chip mounted to corresponding mounting pads and thereby connected to other electronics that can receive power from the battery.