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Embedded solid-state battery

  • US 9,627,717 B1
  • Filed: 10/16/2012
  • Issued: 04/18/2017
  • Est. Priority Date: 10/16/2012
  • Status: Active Grant
First Claim
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1. A method for manufacturing of a solid-state electrochemical device, the method comprising:

  • forming, using at least a process chamber, a plurality of first strip regions overlying a surface region of a substrate member coupled to a transfer device, the transfer device being selected from at least one of a drum device, a roll-to-roll device, a plate device or a belt device, each of the first strip regions comprising a stack of thin film electrochemical devices, each of the thin film electrochemical devices comprising at least an anode material, a cathode material, and an electrolyte material, the plurality of first strip regions being configured in a first direction along a length of the surface region of the substrate and being normal to a second direction, the second direction being normal to the first direction;

    forming a first gap region associated with each of the plurality of strip regions using a removal process, each of the plurality of first strip regions having a first thickness above the surface region, the removal process being selected from one of a shadow masking removal or ablation process or a laser ablation process to cause formation of a plurality of strips configured with the plurality of first gap regions, each of which is separating a pair of strips;

    forming a fill material overlying the plurality of first strips and plurality of first gap regions to substantially fill each of the first gap regions and substantially enclose each of the plurality of first strips and forming a planarized first upper surface region overlying the plurality of strips;

    successively repeating the process of forming the plurality of strip regions, the plurality of gap regions, and forming the fill material overlying the planarized first upper surface region N times, where N is an integer greater than two (2) to form multiple plurality of strips configured as a vertical stack structure enclosed in the fill material overlying the substrate member,removing the substrate member including the vertical stack structure including the multiple plurality of strips from the transfer device, while maintaining the substrate member having the multiple plurality of strips intact and enclosed in fill material;

    selectively separating one or more of the plurality of strips to form an encapsulated portion of one of the multiple strips enclosed in fill material;

    exposing a first conductor from a first side of the encapsulating portion of one of the multiple strips and exposing a second conductor from a second side of the encapsulating portion of one of the multiple strips;

    forming a first electrode member electrically and mechanically coupled to the first conductor and forming a second electrode member electrically and mechanically coupled to the second conductor; and

    providing a discrete battery device.

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