Manufacturing Scale-Up of Anodeless Solid-State Lithium Thin-Film Batteries for High Volumetric Energy Density Applications
Diyi Cheng, Khanh Tran, Shoba Rao, Zhongchun Wang, Richard van der Linde, Shahid Pirzada, Hui Yang, Alex Yan, Arvind Kamath, Ying Shirley Meng
Abstract
High Resolution Image Download MS PowerPoint Slide Compact, rechargeable batteries in the capacity range of 1–100 mAh are targeted for form-factor-constrained wearables and other high-performance electronic devices, which have core requirements including high volumetric energy density (VED), fast charging, safety, surface-mount technology (SMT) compatibility, and long cycle life. To maximize the VED, anodeless solid-state lithium thin-film batteries (TFBs) fabricated by using a roll-to-roll process on an ultrathin stainless-steel substrate (10–75 μm in thickness) have been developed. A high-device-density dry-process patterning flow defines customizable battery device dimensions while generating negligible waste. The entire fabrication operation is performed in a conventional, humidity-controlled cleanroom, eliminating the need for a costly dry-room environment and allowing for simplified, lower-cost manufacturing. Such scale-up using an anodeless architecture also enables a thermal-budget-compatible packaging and metallization scheme targeted at industry-compatible SMT processes. Further manufacturability improvements, such as the use of high-speed tests, add to the overall range of elements necessary for mass production.