Sakti3, Inc.

Dyson Technology Limited

Xiangchun Zhang

Ann Marie Sastry

Chia-Wei Wang

Yen-Hung Chen

Myoungdo Chung

HyonCheol Kim

Svetlana Lukich

Thomas V Weigman

Marc Guy Langlois

Steve Buckingham

A method for fabricating a solid state battery device. The device can include electrochemically active layers and an overlaying barrier material, with an inter-digitated layer structure configured with a post terminated lead structure. The method can include forming a plurality of battery device cell regions (-N) formed in a multi-stacked configuration, wherein each of the battery device cell regions comprises a first current collector and a second current collector. The method can also include forming a thickness of a first and second lead material to cause formation of a first and second lead structure to interconnect each of the first and second current collectors associated with each of the plurality of battery device cell regions and to isolate each of the second current collectors extending spatially outside of the battery device cell region within a first and second isolated region, respectively.

Packaging and termination structure for a solid state battery

A high speed deposition apparatus for the manufacture of solid state batteries. The apparatus can be used for the manufacture of solid state multilayer stacked battery devices via a vacuum deposition process. In various embodiments, the manufacturing apparatus can include a containment vessel, a reactor region, a process region, a work piece, one or more vacuum chambers, and an energy source. A complete stack of battery layers can be manufactured in a single vacuum cycle, having background gas, pressure, and deposition rate optimized and controlled for the deposition of each layer. The work piece can include a drum and a substrate, which can be a commercial polymer or metallic web, that are temperature controlled. Masks can be used to delineate or shape layers within the multi-layer stacked electrochemical device manufactured by embodiments of the apparatus.

Multilayer electrochemical device

A method of producing a monolithically integrated high energy density solid-state battery device. The method can include positioning a substrate and depositing one or more stacked monolithically integrated high energy density solid-state electrochemical cells in series or in parallel configurations sequentially or individually. Each of these cells can have a first barrier layer, a cathode current collector deposited overlying the first barrier layer, a cathode overlying the electrically conductive layer, an anode, an anode current collector deposited overlying the solid state layer of negative electrode material, and a second barrier layer. The method can also include rapidly heating the one or more stacked cells to a target temperature for at least 60 minutes, and connecting and terminating the one or more stacked monolithically integrated high energy density solid-state electrochemical cells electrically in series or in parallel, to from a monolithically integrated high energy density solid-state battery device.

High energy density multilayer battery cell with thermally processed components and method for making same

A method of fabricating a multilayered thin film solid state battery device. The method steps include, but are not limited to, the forming of the following layers: substrate member, a barrier material, a first electrode material, a thickness of cathode material, an electrolyte, an anode material, and a second electrode material. The formation of the barrier material can include forming a polymer material being configured to substantially block a migration of an active metal species to the substrate member, and being characterized by a barrier degrading temperature. The formation of cathode material can include forming a cathode material having an amorphous characteristic, while maintaining a temperature of about &#x2212;40 Degrees Celsius to no greater than 500 Degrees Celsius such that a spatial volume is characterized by an external border region of the cathode material. The method can then involve transferring the resulting thin film solid state battery device.

Amorphous cathode material for battery device

A pulsed laser can be used to ablate the desired thin film layers at a desired location, to a desired depth, without impinging significantly upon other layers. The battery cell layer order may be optionally optimized to aid in ease of laser ablation. The laser process can isolate layers of thin film within sufficient proximity to at least one edge of the final thin film battery stack to optimize active battery area.

Laser ablation for manufacture of battery cells

A method for fabricating a solid state battery device. The device can include electrochemically active layers and an overlaying barrier material, with an inter-digitated layer structure configured with a post terminated lead structure. The method can include forming a plurality of battery device cell regions (1-N) formed in a multi-stacked configuration, wherein each of the battery device cell regions comprises a first current collector and a second current collector. The method can also include forming a thickness of a first and second lead material to cause formation of a first and second lead structure to interconnect each of the first and second current collectors associated with each of the plurality of battery device cell regions and to isolate each of the second current collectors extending spatially outside of the battery device cell region within a first and second isolated region, respectively.

A method and system for recharging a solid state battery device. The method can include providing the solid state battery in a fully or partially discharged state. The solid state battery can be coupled to a pair of electrodes. An energy source coupled to the electrodes can be used to supply energy to the solid state battery. This supply of energy can use a first constant current recharge process followed by a constant voltage recharge process. This supply of energy can cause an increase of an energy level of the solid state battery to the maximum energy level within a predetermined amount of time. The predetermined amount of time can be determined as being less than a time period associated with recharging the solid state battery using solely a constant current recharge process.

Method and system for recharging a solid state battery

A method and system for designing a manufacturing facility for solid state thin film battery devices. The method can include providing a plurality of processing tools for arrangement within a predetermined spatial region of one or more manufacturing facilities. A plurality of variables can be assigned for the plurality of processing tools. A target financial variable can be defined to evaluate different manufacturing processing tool configurations. The plurality of variables in the tensor relationship can be processed to reduce a magnitude of the target variable. An optimized set of the plurality of processing tools and respective configuration with the plurality of tools associated with the reduced magnitude of the target variable can be determined through processing. The optimized set of the plurality of processing tools in the respective configuration can be used in the one or more manufacturing facilities for the manufacture of a solid state thin film battery device.

Methodology for design of a manufacturing facility for fabrication of solid state hybrid thin film energy storage and conversion devices

A method of designing and manufacturing a solid-state electrochemical battery cell for a battery device. The method includes building a database of a plurality of first characteristics of a solid-state cells for a battery device and determining at least a third characteristic of the solid-state cell for a given application. The method also includes selecting at least one material of the solid-state electrochemical battery cell, the selected material being from the plurality of first characteristics and forming a plurality of factorial combinations of each component using the selected plurality of first characteristics to derive a respective plurality of solid-state electrochemical battery cells. The method performs a design optimization process for the third characteristic. A step of identifying an optimal design of the second characteristics with the selected first characteristics for each solid-state electrochemical battery cell from the plurality of solid-state cells is included.

Computer aided solid state battery design method and manufacture of same using selected combinations of characteristics

A method of the present invention using a prediction process including a battery equivalent circuit model used to predict a voltage and a state of charge of a battery. The equivalent circuit battery model includes different equivalent circuit models consisting of at least an ideal DC power source, internal resistance, and an arbitrary number of representative parallel resistors and capacitors. These parameters are obtained a priori by fitting the equivalent circuit model to battery testing data. The present invention further uses a correction process includes determining a corrected predicted state of charge of the battery; and storing the corrected state of charge of the battery in a storage medium. In the present invention, an expectation of the predicted voltage of the battery and an expectation of the predicted state of charge of the battery are obtained by an unscented transform with sigma points selected by a Gaussian process optimization.

Method and system for operating a battery in a selected application

A method of determining at least one material property of at least one component of an electrochemical system (fully or partially completed) using a process to reduce a difference of a performance characteristic between a numerical simulation result of a physical model and an empirical result. The method includes providing an electrochemical cell using a thin film process and performing a plurality of tests on the electrochemical cell to identify one or more target performance characteristics of the electrochemical cell. The method includes performing a surrogate based analysis process and determining a plurality of outputs of the surrogate based analysis function and determines a value of the unknown material property.

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Ann Arbor, MI, United States of America

Xiangchun Zhang