Solid-State Thin Film Battery Fabrication Device
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Solution Overview
Problem
Conventional electrochemical batteries using liquid or gel electrolytes face safety concerns such as flammability and trade-offs between energy density and power density, which are not effectively addressed in existing technologies.
Innovation Solution
The development of a solid-state thin film battery fabrication device with multiple chambers, utilizing a Knudsen cell for lithium deposition and self-aligned layer deposition techniques, eliminates the use of flammable liquids by employing solid electrolytes and optimizing energy and power density through specific layer configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid or gel electrolytes are used in conventional batteries, then ionic conductivity is improved, but safety deteriorates due to flammability
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid/gel to solid thin film form. This parameter change eliminates flammability while maintaining ionic conductivity through careful selection of solid electrolyte materials and optimization of film thickness and composition.
Solution Approach 2:
The invention employs phase transition by using solid electrolyte materials that undergo controlled phase changes during battery operation. The solid electrolyte maintains structural integrity while allowing ion transport, achieving both safety and conductivity.
2Quantity of substance
If energy density is increased in batteries, then power density trade-offs worsen, but if power density is increased, then energy density trade-offs worsen
Solution Approach 1:
The patent transitions from conventional bulk battery architecture to thin film geometry, adding a dimensional advantage. The reduced thickness in one dimension enables both high energy density (through material efficiency) and high power density (through reduced ion transport paths), breaking the traditional trade-off.
Solution Approach 2:
The invention applies different material compositions and structures to different layers of the thin film battery. Each layer is optimized locally for its specific function, enabling overall optimization of both energy and power density without compromise.
3Manufacturing precision
If multiple deposition chambers are used for layer fabrication, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the fabrication process into separate chambers, each dedicated to depositing specific layers. This segmentation allows independent optimization of each deposition process while maintaining overall system manageability through modular design.
Solution Approach 2:
The invention employs self-aligned deposition techniques where previously deposited layers automatically serve as alignment references for subsequent layers. This self-service mechanism eliminates the need for complex external alignment systems, reducing device complexity while maintaining precision.
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 approach enhances safety, scalability, and energy capacity while minimizing charge/discharge cycle degradation and dendrite formation, achieving better optimization of high energy capacity with high power density and improved safety compared to traditional batteries.
Implementation Method 1
A Knudsen cell is coupled to the third chamber and configured to deposit lithium on a battery being fabricated
Implementation Method 2
The first magnetron is a direct current (DC) sputtering gun configured to provide LiCoO2 particles during a first polar conductor deposition step
Implementation Method 3
The first chamber further comprises a pump configured to evacuate at least the first chamber and the second chamber via the hollow shaft
Data Source
AI summary
A solid state electrochemical battery fabrication device and a method of creating the solid state electrochemical battery are provided. There is a first chamber comprising a first magnetron and a second chamber comprising a second magnetron, coupled to the first chamber. There is a third chamber comprising a vapor source for a polymer deposition, coupled to the second chamber. A Knudsen cell is coupled to the third chamber and configured to deposit lithium on a battery being fabricated. A linear hollow shaft connects the first, second, and third chambers, and provides a hermetic seal. A first telescopic arm having a housing is coupled to a first end of the hollow shaft and configured to extend out of its housing from the first chamber to the second chamber.