Solid-State Battery Packaging and Termination Structure
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Solution Overview
Problem
Current manufacturing techniques for solid-state thin film batteries are limited to only a few stacked cells due to manufacturing problems, preventing their widespread use in consumer electronics and automobiles, and existing packaging methods are cumbersome and expensive, failing to provide adequate protection against atmospheric elements.
Innovation Solution
A method for manufacturing solid-state thin film batteries with an inter-digitated layer structure and post-terminated lead structure, using deposition processes to form lead materials for termination and packaging, and incorporating internal packaging layers for hermetic sealing and moisture barrier protection, allowing for multi-stacked configurations and high energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional packaging methods are used for solid-state batteries, then the batteries are protected from atmospheric elements, but the packaging is cumbersome and expensive
Solution Approach 1:
The patent merges the packaging function with the battery structure itself by integrating sealing layers and protective coatings directly into the battery assembly process. The packaging layers are deposited conformally over the three-dimensional battery structure, combining structural support, sealing, and protection functions into a single integrated component rather than separate packaging elements.
Solution Approach 2:
The patent employs thin film packaging layers deposited through physical vapor deposition or chemical vapor deposition processes. These flexible thin films conform to the battery's three-dimensional structure while providing hermetic sealing and protection from atmospheric elements, replacing cumbersome rigid packaging with lightweight flexible barriers.
2Quantity of substance
If multi-stacked battery configurations are manufactured, then energy density is improved, but manufacturing problems limit production to only a few stacked cells
Solution Approach 1:
The patent segments the battery into multiple thin-film stacked cells that can be manufactured independently and then assembled. Each cell layer is deposited separately through sputtering or evaporation processes, allowing for precise control of individual cell properties and facilitating quality inspection between stacks, thereby enabling production of multi-cell configurations.
Solution Approach 2:
The patent transitions from planar two-dimensional battery structures to three-dimensional stacked configurations by depositing multiple active layers vertically. This dimensional change increases the quantity of active material per unit area, thereby improving energy density while maintaining manufacturability through sequential deposition processes.
3Reliability
If lead structures are formed for termination, then electrical connections are established, but parasitic mass and volume increase
Solution Approach 1:
The patent extracts the lead material only where absolutely necessary for electrical termination, removing excess lead that would otherwise be present in conventional batteries. The lead is deposited selectively through masking techniques to form minimal interconnection structures that establish electrical connections between stacked cells without adding unnecessary parasitic mass.
Solution Approach 2:
The patent applies local quality by varying the lead distribution throughout the battery structure - concentrated where electrical connections are needed at termination points, and absent or minimal in active regions. This localized lead placement ensures reliable electrical connectivity while minimizing parasitic mass in non-critical areas.
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
Enables the production of solid-state batteries with improved energy density and reduced parasitic mass and volume, providing effective electrical, mechanical, and environmental protection, facilitating their use in various applications including consumer electronics and vehicles.
Implementation Method 1
forming, using at least a first deposition process, a thickness of first lead material to cause formation of a first lead structure to interconnect each of the first current collectors
Data Source
AI summary
A method for fabricating a solid state battery device. The device can include electrochemically active layers and an overlaying barrier material, with an inter-digitated layer structure configured with a post terminated lead structure. The method can include forming a plurality of battery device cell regions (1-N) formed in a multi-stacked configuration, wherein each of the battery device cell regions comprises a first current collector and a second current collector. The method can also include forming a thickness of a first and second lead material to cause formation of a first and second lead structure to interconnect each of the first and second current collectors associated with each of the plurality of battery device cell regions and to isolate each of the second current collectors extending spatially outside of the battery device cell region within a first and second isolated region, respectively.