Solid-State Battery Thin-Film Stacking for Fast Charging

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Solution Overview

Problem

Conventional solid-state lithium-based batteries have limited charging speed and capacity, primarily due to high resistive cathode materials and interfacial energy issues, which hinder their use in portable electronic devices that require fast charging and high energy storage without being bulky or toxic.

Innovation Solution

The development of solid-state battery structures featuring vertically stacked or arrayed thin-film batteries with fuse elements and via-filled contact structures, utilizing non-toxic materials and a solid-state electrolyte, to enhance charging speed and capacity beyond 3C and 1 Ah, respectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional solid-state lithium-based batteries are used, then safety and non-toxicity are improved, but charging speed is limited to below 3C

Engineering Contradiction:

ImprovesafetyVSAvoidcharging speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The battery is divided into multiple thin-film battery sub-sheets (each 100 μm or less in thickness) that are vertically stacked. Each sub-sheet functions as an independent electrochemical cell, allowing parallel charge/discharge pathways that collectively achieve high capacity while maintaining fast charging rates above 3C through the segmented architecture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from planar battery arrangement to three-dimensional vertical stacking of thin-film sub-sheets. This dimensional change increases the effective surface area for electrochemical reactions without increasing the battery's footprint, enabling both fast charging and high capacity simultaneously through enhanced ion transport pathways in the vertical dimension

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If battery capacity is increased to power portable devices, then energy storage is improved, but battery size and weight increase

Engineering Contradiction:

Improveenergy storageVSAvoidbattery weight

Core Design Contradiction:

Quantity of substanceVSWeight of moving object

Solution Approach 1:

The battery employs thin-film sub-sheets with thickness of 100 μm or less, utilizing thin-film deposition techniques to create lightweight yet high-capacity energy storage structures. The thin-film architecture provides high surface-area-to-volume ratio, maximizing energy density while minimizing weight for portable electronic devices

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The battery utilizes composite material structures including solid-state electrolytes combined with thin-film electrodes and protective coatings. These composite materials enable high energy storage capacity while maintaining lightweight properties, as the composite architecture optimizes both electrochemical performance and mass efficiency

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional battery materials are used, then manufacturing is simplified, but toxic and flammable materials are present

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidtoxicity

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention changes the physical and chemical parameters of the electrolyte from liquid to solid state, eliminating flammability and leakage issues while maintaining ionic conductivity. This parameter change allows the use of non-toxic solid materials such as lithium phosphorus oxynitride (LiPON) that can be deposited using conventional thin-film techniques, preserving manufacturing simplicity while eliminating harmful properties

Inventive Principle:

Principle #35Parameter changes

4Stability of the object's composition

If high resistive cathode materials are used, then battery stability is improved, but charging speed is limited

Engineering Contradiction:

Improvecathode stabilityVSAvoidcharging speed

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The cathode is constructed as a thin-film layer that reduces ion transport distance and interfacial resistance. The thin-film architecture allows stable cathode materials to achieve fast charging by minimizing the path length for lithium ion diffusion, thereby maintaining compositional stability while enabling charging rates above 3C through reduced transport resistance

Inventive Principle:

Principle #30Flexible shells and thin films

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

These structures enable fast charging and high-capacity solid-state lithium-based batteries, addressing the limitations of conventional batteries by providing safer, lighter, and more efficient energy storage for portable devices.

Implementation Method 1

a solid-state electrolyte layer (18) formed over the cathode layer (16)

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Data Source

PatentUS10673097B2High charge rate, large capacity, solid-state battery

Publication Date: 2020.06.02 INTERNATIONAL BUSINESS MACHINE CORPORATION

AI summary

Solid-state battery structures, particularly solid-state lithium-based battery structures, which are fast charging and have a high capacity are provided. Notably, fast charging, high capacity solid-state battery structures are provided that include a plurality of solid-state-thin-film batteries that are stacked one atop the other, or that include an array of interconnected solid-state thin-film batteries, or that contain a solid-state thin-film battery located on physically exposed surfaces of fin structures.