Silicon Substrate Current Collector with Metal Silicide Layers
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Solution Overview
Problem
Existing substrate materials for bipolar lead acid batteries face challenges such as corrosion, passivation, and inadequate electronic or ionic conductivity, which affect the battery's performance and longevity.
Innovation Solution
A silicon substrate with metal silicide layers is used as a current collector, where different silicides are formed on opposite sides to provide a stable and conductive interface for the active materials, enhancing electrochemical stability and preventing corrosion while allowing for high electronic conductivity and low ionic conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional substrate materials are used for bipolar lead acid batteries, then the battery can be assembled with basic structural integrity, but the substrate suffers from corrosion, passivation, and inadequate electronic or ionic conductivity which deteriorates battery performance and longevity
Solution Approach 1:
The patent employs a composite substrate structure consisting of a silicon base material combined with metal silicide layers (such as nickel silicide, cobalt silicide, or tungsten silicide). This composite approach leverages the high conductivity of silicon while the metal silicide layers provide corrosion resistance and stable electrochemical interfaces, thereby simultaneously improving reliability and preventing harmful corrosion effects.
Solution Approach 2:
The patent modifies the substrate's electrochemical parameters by forming metal silicide layers on the silicon substrate through controlled thermal processing. These silicide layers alter the surface properties and electrochemical stability of the substrate, changing its resistance to corrosion and passivation while maintaining or enhancing electronic conductivity, thus resolving the contradiction between stability and harmful factors.
2Power
If the substrate provides high electronic conductivity for efficient current collection, then battery power output improves, but the substrate becomes more susceptible to corrosion and passivation in the electrolyte environment
Solution Approach 1:
The patent creates a composite structure where highly conductive silicon serves as the bulk material for efficient current collection, while metal silicide layers form protective surface layers that resist corrosion. This composite architecture enables the substrate to maintain high electronic conductivity for power output while the silicide layers provide the necessary corrosion resistance for reliability.
Solution Approach 2:
The patent applies different material properties to different regions of the substrate: the bulk silicon provides high electronic conductivity for power collection, while the surface metal silicide layers provide corrosion resistance. This local differentiation of material qualities allows the substrate to simultaneously achieve high power output and reliable corrosion resistance in the electrolyte environment.
3Duration of action of stationary object
If the substrate forms stable electrochemical interfaces with active materials, then battery longevity improves, but the manufacturing process becomes more complex requiring precise deposition and annealing control
Solution Approach 1:
The patent performs preliminary actions during substrate fabrication by depositing metal layers and forming silicide phases through controlled annealing before assembling the battery. This preliminary formation of stable electrochemical interfaces ensures long-term battery lifespan, while the processes are integrated into the existing manufacturing workflow to manage complexity.
Solution Approach 2:
The patent utilizes controlled parameter changes during thermal processing to transform deposited metal layers into stable metal silicide phases. By precisely controlling annealing temperature and atmosphere parameters, the process creates durable electrochemical interfaces that extend battery lifespan, while these parameter controls are implemented as standardized manufacturing 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
The silicon substrate with metal silicide layers improves the energy density, reduces gas evolution, and extends the battery's lifespan by providing a stable electrochemical window and preventing corrosion, thus enhancing the overall performance of the bipolar lead acid battery.
Implementation Method 1
The first and second metal layers can be annealed to form a first silicide on the first surface and a different second silicide on the second surface of the rigid silicon substrate
Implementation Method 2
annealing the first metal layer to form the first silicide using a first annealing temperature range, and separately annealing the second metal layer to form the second silicide using a second annealing temperature range
Data Source
AI summary
Apparatus and techniques are described herein for providing a bipolar battery plate such as can be included as a portion of an energy storage device assembly, such as a battery. The bipolar battery plate can include a silicon substrate. A first metal layer can be deposited on a first surface of the rigid silicon substrate, and a different second metal layer can be deposited on a second surface of the rigid silicon substrate opposite the first surface. The first and second metal layers can be annealed to form a first silicide on the first surface and a different second silicide on the second surface of the rigid silicon substrate.