Energy storage device

Patent metadata

Field	Value
Publication number	US-12062818-B2
Application number	US-201917261522-A
Country	US
Kind code	B2
Filing date	Jul 19, 2019
Priority date	Jul 20, 2018
Publication date	Aug 13, 2024
Grant date	Aug 13, 2024

Abstract

A method for manufacturing an energy storage device. A stack is provided on a substrate. The stack comprises a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer. The method includes forming a first groove, a second groove, and a third groove in a first side of the stack opposite to a second side of the stack on the substrate. The first groove has a first depth and a first surface comprising a first exposed surface of the second electrode layer. The second groove has a second depth different from the first depth and a second surface comprising an exposed surface of the first electrode layer. The third groove has a third depth substantially the same as the first depth and a third surface comprising a second exposed surface of the second electrode layer.

First claim

The invention claimed is:

1. A method for manufacturing an energy storage device, the method comprising:
providing a stack on a surface of a substrate, the stack comprising a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer, the first electrode layer closer than the second electrode layer to the surface of the substrate;
forming a first groove in a first side of the stack, the first side of the stack opposite to a second side of the stack on the surface of the substrate, the first groove having a first depth and a first surface comprising a first exposed surface of the second electrode layer;
forming a second groove in the first side of the stack, the second groove having a second depth different from the first depth and a second surface comprising a first exposed surface of the first electrode layer;
forming a third groove in the first side of the stack, the third groove having a third depth the same as the first depth and a third surface comprising a second exposed surface of the second electrode layer, wherein the second groove is between the first groove and the third groove;
providing a first electrical insulator in contact with the first exposed surface of the first electrode layer and a first exposed surface of the electrolyte layer without contacting at least a portion of the first exposed surface of the second electrode layer; and
providing a second electrical insulator in contact with the second exposed surface of the second electrode layer and a second exposed surface of the electrolyte layer without contacting at least a portion of a second exposed surface of the first electrode layer.

2. The method of claim 1 , wherein at least one of: the first groove, the second groove, or the third groove are formed without cutting the substrate.

3. The method of claim 1 , wherein:
the first groove is spaced apart from, and parallel to, the second groove; and
the second groove is spaced apart from, and parallel to, the third groove.

4. The method of claim 1 , wherein at least one of: the first depth of the first groove, the second depth of the second groove, or the third depth of the third groove is perpendicular to a plane of the surface of the substrate.

5. The method of claim 1 , wherein forming the first groove, forming the second groove and forming the third groove uses at least one laser beam directed towards the first side of the substrate.

6. The method of claim 1 , wherein:
the first groove is formed through the second electrode layer and the electrolyte layer and exposes the first exposed surface of the second electrode layer;
the second groove is formed through the second electrode layer, the electrolyte layer and the first electrode layer and exposes the first exposed surface of the first electrode layer; and
the third groove is formed through the second electrode layer and the electrolyte layer and exposes the second exposed surface of the second electrode layer.

7. The method of claim 6 , wherein:
the first groove is formed without cutting the first electrode layer and without cutting the substrate;
the second groove is formed without cutting the substrate; and
the third groove is formed without cutting the first electrode layer and without cutting the substrate.

8. The method of claim 1 , comprising providing an electrically insulating material in at least one of:
the first groove, to insulate the first exposed surface of the second electrode layer from the first electrode layer;
the second groove, to insulate the first exposed surface of the first electrode layer from the second electrode layer; or
the third groove, to insulate the second exposed surface of the second electrode layer from the first electrode layer.

9. The method of claim 8 , comprising, after providing the electrically insulating material in the second groove, removing a portion of the electrically insulating material to expose a third exposed surface of the second electrode layer.

10. The method of claim 1 , comprising:
forming, in the first side of the stack, a first precursor groove, a second precursor groove and a third precursor groove; and
providing an electrically insulating material in the first precursor groove, the second precursor groove and the third precursor groove, wherein:
the first groove is formed through the electrically insulating material in the first precursor groove;
the second groove is formed through the electrically insulating material in the second precursor groove; and
the third groove is formed through the electrically insulating material in the third precursor groove.

11. The method of claim 10 , wherein the first precursor groove, the second precursor groove and the third precursor groove are formed having the same depth as each other.

12. The method of claim 10 , wherein:
the stack comprises a further first electrode layer, a further second electrode layer and a further electrolyte layer between the further first electrode layer and the further second electrode layer, the further first electrode layer located between the second electrode layer and the further electrolyte layer; and at least one of:
forming the first groove comprises:
forming the first groove through the electrically insulating material in the first precursor groove to form the first groove with the first surface comprising the first exposed surface of the second electrode layer and such that a first exposed surface of the further second electrode layer is insulated from the first groove by the electrically insulating material; and
widening the first groove such that the first surface further comprises the first exposed surface of the further second electrode layer;
forming the second groove comprises:
forming the second groove through the electrically insulating material in the second precursor groove to form the second groove with the second surface comprising the first exposed surface of the first electrode layer and such that an exposed surface of the further first electrode layer is insulated from the second groove by the electrically insulating material; and
widening the second groove such that the second surface further comprises the exposed surface of the further first electrode layer; or
forming the third groove comprises:
forming the third groove through the electrically insulating material in the third precursor groove to form the third groove with the third surface comprising the second exposed surface of the second electrode layer and such that a second exposed surface of the further second electrode layer is insulated from the third groove by the electrically insulating material; and
widening the third groove such that the third surface further comprises the second exposed surface of the further second electrode layer.

13. The method of claim 12 , wherein at least one of:
after widening the first groove, a first portion of the first groove is narrower than a second portion of the first groove, the first portion of the first groove closer than the second portion of the first groove to the first side of the substrate;
after widening the second groove, a first portion of the second groove is narrower than a second portion of the second groove, the first portion of the second groove closer than the second portion of the second groove to the first side of the substrate; and
after widening the third groove, a first portion of the third groove is narrower than a second portion of the third groove, the first portion of the third groove closer than the second portion of the third groove to the first side of the substrate.

Assignees

• Dyson Technology Ltd

Inventors

• Howard Joseph Daniel
• Rendall Michael Edward

Classifications

• H01M10/0585 Primary

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M10/0562

  Solid materials · CPC title

• H01M10/0431 Primary

  Cells with wound or folded electrodes (H01M10/045 takes precedence) · CPC title

• H01M4/8832

  Ink jet printing · CPC title

• H01M2300/0068

  inorganic · CPC title