Sheet-Type Discrete Element for Thin Film Storage Substrates

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Solution Overview

Problem

Conventional thin film storage elements face challenges such as high reactivity of metallic lithium, substrate material limitations, especially regarding thermal stability and moisture resistance, and issues with layer adhesion and uniformity, leading to defects like cracks and detachment during the manufacturing process.

Innovation Solution

A sheet-type discrete element with specific properties, including high thermal stability, low moisture transmission, and adjustable UV transmittance, is used as a substrate to ensure uniform layer deposition and prevent defects, featuring a thickness variation of less than 25 μm and a composition that includes TiO2 to reduce transition metal diffusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If metallic lithium is used as anode material to achieve high energy density, then energy density is improved, but reactivity with moisture and air increases leading to safety concerns and handling difficulties

Engineering Contradiction:
Improveenergy densityVSAvoidreactivity with moisture and air
Core Design Contradiction:
Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an intermediate layer between the metallic lithium anode and the environment (moisture and air). This intermediary layer acts as a protective barrier that prevents direct contact between the reactive lithium and harmful external factors, thereby maintaining high energy density while reducing safety concerns and handling difficulties.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Manufacturing precision

If thin film storage elements are manufactured with complex coating processes to achieve precise layer deposition, then manufacturing precision is improved, but device complexity and production cost increase

Engineering Contradiction:
Improvelayer deposition uniformityVSAvoidmanufacturing process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-treating the substrate surface before coating to enhance layer adhesion and uniformity. This preliminary preparation step simplifies subsequent coating processes by creating an optimized surface that naturally promotes even deposition, thereby reducing the need for complex multi-step coating procedures while maintaining high manufacturing precision.

Inventive Principle:
Principle #10Preliminary action

3Manufacturing precision

If substrate thickness variation is reduced to prevent layer defects, then manufacturing precision is improved, but substrate production complexity increases

Engineering Contradiction:
Improvesubstrate thickness uniformityVSAvoidsubstrate production complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent employs parameter changes by optimizing the substrate production parameters (such as temperature, pressure, and material composition) to achieve uniform thickness with reduced variation. By carefully controlling and adjusting these parameters during substrate manufacturing, the patent achieves high thickness uniformity that prevents layer defects like cracks and detachment, while avoiding excessive production complexity through systematic parameter optimization.

Inventive Principle:
Principle #35Parameter changes

4Reliability

If encapsulation is added to protect against moisture to ensure reliability, then reliability is improved, but device complexity and production cost increase

Engineering Contradiction:
Improveprotection against moistureVSAvoidencapsulation structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing the substrate to serve multiple functions: it acts as both the structural base and the primary moisture barrier. By integrating the encapsulation function directly into the substrate material or structure, the patent eliminates the need for separate encapsulation layers, thereby improving reliability through moisture protection while reducing device complexity and production costs.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS10418658B2Electrical storage system comprising a disc-shaped discrete element, discrete element, method for the production thereof, and use thereof
Publication Date: 2019.09.17 SCHOTT AG
  • US10418658B2 patent drawing
  • US10418658B2 patent drawing

AI summary

An electrical storage system is provided that has a thickness of less than 2 mm, which includes at least one sheet-type discrete element. The sheet-type discrete element exhibits high resistance against an attack of transition metals or transition metal ions, in particular titanium, wherein the sheet-type discrete element contains titanium. The invention also relates to a sheet-type discrete element for use in an electrical storage system, which exhibits high resistance to the attack of transition metals or of transition metal ions, in particular titanium.