Solid-State Battery Cell Templates for Stable 3D Electrode Coating
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Solution Overview
Problem
Current methods for fabricating solid-state batteries with three-dimensional electrode structures face challenges in conformal coating of active electrode materials and maintaining mechanical stability, due to issues with barrier layer removal in porous anodic aluminum oxide templates and the instability of acidic electroplating baths.
Innovation Solution
A method involving anodization of valve metals to form templates with spaced channels, followed by protective treatment and controlled etching to remove barrier layers, allowing for conformal deposition of active electrode materials without pore widening or narrowing, and using neutral electroplating baths for large-scale manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the barrier layer is removed by immersing the template in H3PO4 solution, then the barrier layer is removed from channel bottoms, but excessive pore widening occurs resulting in large diameter nanowires that limit energy density
Solution Approach 1:
A thin metal layer is deposited on the channel bottoms before removing the barrier layer. This preliminary action provides mechanical support to prevent excessive pore widening during subsequent H3PO4 etching, while still allowing complete barrier layer removal for reliable nanowire formation.
Solution Approach 2:
The metal layer acts as an intermediary between the barrier layer removal process and the final pore structure. It mediates the etching process by providing structural support that prevents uncontrolled pore widening, enabling complete barrier layer removal without sacrificing pore volume for active material.
2Manufacturing precision
If the voltage is gradually reduced during the final stage of anodization, then the barrier layer thickness is reduced to allow electroplating, but long thin root-like nanowires are formed resulting in poor mechanical stability
Solution Approach 1:
A metal layer is deposited as an intermediary structure at the channel bottoms before nanowire formation. This metal layer acts as a robust foundation that replaces the mechanically weak root-like nanowires, providing strong mechanical support while allowing the barrier layer to be sufficiently thin for electroplating.
Solution Approach 2:
The metal layer is deposited in advance before the barrier layer removal and nanowire formation steps. This preliminary action establishes a strong mechanical foundation that prevents the formation of weak root-like structures, ensuring both manufacturability and mechanical stability.
3Ease of manufacture
If electroplating is performed in acidic baths, then metal nanowires can be formed, but the electroplating process is unstable and difficult to implement in large-scale manufacturing
Solution Approach 1:
The pH parameter of the electroplating bath is changed from acidic to neutral. This parameter change stabilizes the electroplating process, eliminating the instability and reliability issues associated with acidic baths while still enabling effective metal nanowire formation on the prepared channel bottoms.
4Reliability
If the template is separated from the underlying aluminum foil, then the barrier layer can be removed from channel bottoms, but the template becomes fragile and hard to implement in large-scale manufacturing
Solution Approach 1:
A metal layer is deposited on the channel bottoms before barrier layer removal. This preliminary reinforcement allows the barrier layer to be completely removed without requiring template separation, maintaining template integrity and enabling large-scale manufacturing while achieving reliable barrier layer removal.
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 method enables the formation of solid-state battery cells with improved mechanical stability and energy density by maintaining the structural integrity of the electrode structures and ensuring the stability of the electroplating process, suitable for large-scale production.
Implementation Method 1
a plurality of spaced structures are formed by transforming aluminium into anodic aluminium oxide comprising channels by a single anodization step
Implementation Method 2
a first layer of active electrode material is coated on the plurality of spaced structures; an electrolyte layer is deposited over the first layer of active electrode material; a second layer of active electrode material is formed over the electrolyte layer
Data Source
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AI summary
Methods for fabricating solid-state battery cells and batteries are provided, as well as solid-state battery cells and batteries thus fabricated.These methods may relate to the transformation of at least part of a valve metal layer into a template comprising a plurality of spaced (nano)channels, and/or to the formation of a plurality of spaced structures inside the (nano)channels of the template. They may further relate to the formation of a layer of functional material on an electrically conductive substrate.