Solid-State Battery Encapsulation and Via Layout Against Ambient Ingress
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Solution Overview
Problem
Solid-state lithium batteries face challenges in maintaining high cycle life and preventing lithium loss due to ambient ingress, as existing protection methods either compromise charge capacity or add packaging overhead.
Innovation Solution
A stacked solid-state battery design featuring a cathode current collector, solid-state electrolyte, anode current collector, and a conductive redistribution layer, encapsulated with a barrier film and a dummy cell for enhanced protection, allowing for efficient charge distribution and reduced packaging overhead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protection layer is deposited at the cell level, then ambient protection is improved, but the protection layer is diced during device singulation creating entry paths for ambient ingress
Solution Approach 1:
The battery structure is segmented into multiple cells arranged in a grid pattern on a single substrate, with each cell independently encapsulated by barrier/insulation film. This segmentation allows the protection function to be distributed across all cells rather than relying on a single continuous protection layer that would be compromised by dicing.
Solution Approach 2:
The patent transitions from protecting individual cells in isolation to protecting an array of cells on a shared substrate. The barrier/insulation film encapsulates each cell while the overall array structure provides collective protection, adding a dimensional aspect to the protection strategy that avoids the need for post-encapsulation dicing.
2Object-affected harmful factors
If the cell is packaged inside a pouch cell or sandwiched inside moisture-resistant lamination layers, then ambient protection is improved, but packaging overhead increases reducing charge capacity per packaged area and volume
Solution Approach 1:
Multiple battery cells are merged into a single integrated array on one substrate, sharing common structural support and encapsulation. This merging eliminates the need for separate pouch packaging for each cell, reducing overall packaging overhead while maintaining ambient protection through the barrier/insulation film that encapsulates the entire array.
Solution Approach 2:
The barrier/insulation film serves multiple functions simultaneously: it provides moisture and ambient protection, acts as electrical insulation, and enables the cells to be interconnected in series or parallel configurations. This multi-functionality eliminates the need for additional dedicated packaging layers, maximizing charge capacity per packaged area.
3Ease of operation
If the cell is diced or cut during device singulation, then individual devices are obtained, but entry paths for ambient ingress are created on device sidewalls
Solution Approach 1:
The barrier/insulation film encapsulation is applied to all cells in the array before the dicing process. This preliminary action ensures that the protection structure is already in place and designed to accommodate subsequent cutting, with the encapsulation maintaining its integrity and protective function after singulation creates individual devices from the array.
Data Source
AI summary
A solid-state battery and methods of making the same are disclosed. The battery includes a plurality of cells and first and second terminals on opposite sides/edges of the battery. Each cell includes a cathode current collector (CCC), a cathode thereon, a solid-state electrolyte, an anode current collector (ACC), a moat in the cathode and the electrolyte and around the ACC, a barrier/insulation film, a via/opening in the barrier/insulation film exposing the ACC, and a conductive redistribution layer in the via/opening, in the moat, on the barrier/insulation film, and on a first sidewall of each cell. The barrier/insulation film encapsulates the CCC, the cathode, the solid-state electrolyte and the ACC. One terminal is electrically connected to each ACC through the redistribution layer, and the other is electrically connected to each cathode or CCC.