Silicon Wafer Battery System for Custom Geometry Production
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Solution Overview
Problem
Existing battery technologies face challenges in efficiently producing custom battery geometries with high performance and low upfront tooling costs, while maintaining the crystalline structure of silicon wafers and minimizing anode expansion during lithium ion transport.
Innovation Solution
A method involving bulk micro-machining and photolithography processes to create a multi-cell assembly on a silicon wafer, which is then dissected into discrete single-cell batteries, using a cathode and electrolyte material configuration that limits anode expansion and preserves the crystalline structure, allowing for custom geometry and high-volume production with minimal tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom battery geometries are produced using traditional methods, then manufacturing flexibility is improved, but tooling costs and production time increase
Solution Approach 1:
The battery is divided into modular components (cathode segments, anode, electrolyte) that can be independently manufactured and assembled. This segmentation allows custom geometries to be created by combining standard modules rather than requiring custom tooling for each geometry, resolving the contradiction between manufacturing flexibility and tooling costs
Solution Approach 2:
The patent develops universal manufacturing processes and equipment that can produce multiple battery geometries using the same tooling. The cathode can be configured in different geometries (planar, cylindrical, prismatic) using the same base manufacturing equipment, eliminating the need for geometry-specific tooling and reducing upfront costs while maintaining versatility
2Quantity of substance
If silicon anode is used for high capacity, then energy density is improved, but anode expansion and structural instability occur during lithium ion transport
Solution Approach 1:
The patent applies different material properties to different regions of the anode structure. The silicon anode is combined with a stable matrix material (such as carbon or metal oxide) where the silicon provides high lithium capacity in specific regions while the stable matrix maintains overall structural integrity, resolving the contradiction between capacity and stability
Solution Approach 2:
The anode is constructed as a composite material system combining silicon with stable matrix materials. This composite structure allows the silicon to expand and contract during lithium ion transport while the stable matrix maintains the overall anode structure, achieving both high capacity and structural stability
3Productivity
If high-volume production is achieved, then productivity is improved, but manufacturing complexity and quality control difficulty increase
Solution Approach 1:
The patent combines multiple manufacturing steps into integrated processes. For example, the cathode coating, electrolyte saturation, and cell assembly operations are merged into a continuous manufacturing line, enabling high-volume production while simplifying quality control through process integration rather than increasing complexity through multiple separate operations
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 method enables rapid production of custom battery geometries with strong performance characteristics, low internal impedance, and high capacity per unit volume, while maintaining the stability of the silicon anode structure across multiple charge/discharge cycles.
Implementation Method 1
an electrolyte material coating vertical surfaces of each post and vertical surfaces of the continuous wall
Implementation Method 2
A method involving bulk micro-machining and photolithography processes to create a multi-cell assembly on a silicon wafer
Implementation Method 3
minimizing anode expansion during lithium ion transport
Data Source
AI summary
One variation of a battery unit includes: a substrate including silicon and defining a cell, wherein the cell includes a base encompassed by a continuous wall and a set of posts extending normal to the base; an electrolyte material coating vertical surfaces of each post, in the set of posts, and vertical surfaces of the continuous wall in the cell; a cathode material filling the cell over the electrolyte material, between posts in the set of posts, and between the set of posts and the continuous wall; a seal extending along a top of the continuous wall; and a cathode current collector bonded to the seal, electrically coupled to the cathode material, and cooperating with the substrate to enclose the cell to form a single-cell battery.