Thin-Film Energy Storage Cell Connection Using Insulating Interlayers
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Solution Overview
Problem
Existing methods for manufacturing energy storage devices, such as solid-state thin film cells, are complex and inefficient, particularly in connecting the second electrode layer to an external circuit.
Innovation Solution
A method involving the deposition of a current collector layer on a substrate, followed by the deposition of electrically insulating and conductive materials to connect the second electrode layer to the current collector, simplifying the manufacturing process and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrically conductive material is deposited directly to connect the second electrode layer to the external circuit, then the connection is achieved, but the process suffers from variation in ink particle size and rheology effects causing variations in quantity and location of material deposited
Solution Approach 1:
The patent introduces an electrically insulating material layer as an intermediary between the second electrode layer and the electrically conductive material. This mediator provides a controlled substrate for depositing the conductive material, eliminating direct deposition onto the electrode and thereby avoiding rheology effects and particle size variations that cause precision problems.
Solution Approach 2:
The connection structure is segmented into multiple functional layers: the second electrode layer, the electrically insulating material layer, and the electrically conductive material layer. This segmentation allows each layer to perform its specific function independently, with the insulating layer controlling the deposition process and the conductive layer providing electrical connection, thereby improving manufacturing precision.
2Productivity
If electrically conductive material is used directly to connect the second electrode layer to the external circuit, then the connection is achieved, but a larger quantity of material is deposited increasing manufacturing time and material wastage
Solution Approach 1:
The electrically insulating material serves as a mediator that limits the deposition area for the electrically conductive material. By providing a defined substrate with controlled surface area, it prevents excessive material deposition, reducing both material wastage and drying/curing time, thereby improving manufacturing efficiency.
Solution Approach 2:
Instead of depositing electrically conductive material over the entire electrode surface, the insulating material enables partial deposition only where needed for electrical connection. This partial action reduces the quantity of material required, decreases drying time, and eliminates wastage of excess material.
3Reliability
If the manufacturing process uses complex deposition methods for the current collector layer, then the connection is achieved, but the process becomes less controllable and more time-consuming
Solution Approach 1:
The electrically insulating material acts as a mediator that simplifies the deposition of the current collector layer. By providing a prepared substrate with controlled properties, it makes the deposition process more controllable and faster, while the layered structure ensures reliable electrical connection through the conductive material layer.
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 allows for the straightforward and efficient manufacturing of energy storage devices by reducing material usage, simplifying the deposition process, and minimizing the risk of short circuits.
Implementation Method 1
depositing an electrically conductive material on the electrically insulating material to connect the second electrode layer to the at least part of the current collector layer
Implementation Method 2
depositing an electrically insulating material on an exposed surface of the first electrode layer and an exposed surface of the electrolyte layer
Data Source
AI summary
A method comprising providing a first electrode layer on a first portion of a substrate, providing an electrolyte layer on the first electrode layer, and providing a second electrode layer on the electrolyte layer. At least part of a current collector layer is provided on a second portion of the substrate. An electrically insulating material is deposited on an exposed surface of the first electrode layer and an exposed surface of the electrolyte layer. An electrically conductive material is deposited on the electrically insulating material to connect the second electrode layer to the at least part of the current collector layer.