Thin Film Battery Transfer Process for High Energy Density
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Solution Overview
Problem
Existing battery systems face challenges in achieving increased energy capacity and storage density while minimizing inactive materials and overhead, particularly in modern electronics and power systems, due to stringent requirements on substrate materials for high-temperature processing.
Innovation Solution
The implementation of a thin film transfer process where battery layers are deposited and processed on a temporary substrate, then transferred to a thinner, less thermally stable target substrate, reducing the need for high-temperature stability in the final substrate and allowing for a wider range of materials and design choices, thereby increasing active material fraction and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery layers are processed on a temporary substrate requiring high-temperature stability, then manufacturing reliability is improved, but device complexity and inactive material increase due to the need for substrate transfer processes
Solution Approach 1:
The patent uses a temporary substrate as an intermediary carrier that enables high-temperature processing of battery layers. This mediator allows the battery stack to be manufactured under controlled conditions with reliable thermal stability, then transferred to the final application substrate. The temporary substrate serves its purpose during manufacturing and is removed or transferred away, resolving the contradiction between needing high-temperature stability during processing and minimizing inactive materials in the final device.
Solution Approach 2:
The manufacturing process is segmented into distinct phases: (1) depositing battery layers on a temporary substrate capable of withstanding high temperatures, (2) completing thermal processing operations, and (3) transferring the processed battery stack to the final substrate or removing the temporary substrate. This segmentation allows each phase to be optimized independently, achieving manufacturing reliability during processing while eliminating the temporary substrate from the final product.
2Manufacturing precision
If traditional substrate materials are used for high-temperature processing, then manufacturing precision is improved, but energy density decreases due to increased inactive material overhead
Solution Approach 1:
The temporary substrate acts as a mediator during the manufacturing phase, providing the necessary thermal stability for precise high-temperature processing of battery layers. After the battery stack is successfully manufactured with the required precision, the temporary substrate is removed or transferred away, leaving only the thin active battery layers in the final device. This eliminates the overhead of permanent thick substrates, thereby increasing energy density while maintaining manufacturing precision during the critical processing phase.
Solution Approach 2:
The patent applies different substrate qualities to different phases of manufacturing: the temporary substrate provides high thermal stability and mechanical strength during processing, while the final device uses only the thin active battery layers without permanent thick substrate overhead. This local differentiation of material properties allows manufacturing precision to be achieved where needed (during processing) while minimizing inactive materials in the final energy storage device.
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 results in a battery system with enhanced energy density and reduced inactive material, leading to improved performance and cost-effectiveness, with potential energy density increased by minimizing overhead and inactive materials.
Implementation Method 1
The battery stack may be thermally processed on the process substrate in order to generate a phase transition in the cathode layer, for example a crystal phase transition
Implementation Method 2
using an excimer laser to generate a phase transition in the base layer, in order to release the battery stack from the process substrate
Implementation Method 3
The base layer can also be removed, for example by laser ablation
Data Source
AI summary
A battery assembly can be formed on a base layer provided on a substrate, with a thin film battery stack including an anode layer, a cathode layer, and an electrolyte layer between the anode and cathode layers. The thin film battery stack can be attached to a pattern film layer with holes for electrical connection to the anode and cathode layers.