Thin-film Battery

1 . A battery comprising:

a first current collector layer;

a cathode layer deposited on the first current collector layer and comprising a first projection;

an anode layer comprising a second projection;

a solid-state electrolyte layer intermediate the cathode layer and the anode layer, the solid-state electrolyte layer comprising a first recess complementary to the first projection and a second recess complementary to the second projection; and

a second current collector layer deposited over the anode layer.

2 . The battery of claim 1 , wherein the cathode layer comprises a plurality of projections.

3 . The battery of claim 2 , wherein the solid-state electrolyte layer comprises a plurality of recesses complementary to the projections of the cathode layer.

4 . The battery of claim 1 , wherein the anode layer comprises a plurality of projections.

5 . The battery of claim 4 , wherein the solid-state electrolyte layer comprises a plurality of recesses complementary to the projections of the anode layer.

6 . The battery of claim 1 , wherein the solid-state electrolyte layer comprises lithium phosophorus oxynitride.

7 . The battery of claim 1 , wherein the battery is rechargeable.

8 . A method of fabricating a battery comprising:

providing a first current collector;

depositing a cathode layer comprising a first projection on the first current collector;

depositing an electrolyte layer over the cathode layer having a first recess complementary to the first projection;

depositing an anode layer over the electrolyte layer, the anode layer having a second projection complementary to a second recess in the electrolyte layer; and

depositing a second current collector layer over the anode layer.

9 . The method of claim 8 , wherein the at least one of the layers is deposited by three-dimensional printing.

10 . The method of claim 8 , further comprising the step of annealing the cathode layer.

11 . The method of claim 10 , wherein the cathode layer is annealed in-situ as it is deposited.

12 . The method of claim 8 , further comprising the step of curing at least one of the layers.

13 . The method of claim 8 , wherein the cathode and anode layers comprise a plurality of projections with complementary recesses in the electrolyte layer.

14 . The method of claim 8 , further comprising the step of providing positive and negative terminals electrically connected to the first current collector and the second current collector, respectively.

15 . The method of claim 8 , further comprising the step of depositing a protective coating over the second current collector and exposed portions of other layers.

16 . A system comprising:

a bore extending into a portion of earth;

a downhole device disposed within the bore, the downhole device comprising a battery;

the battery comprising a cathode layer deposited on a first current collector layer and comprising a first projection, an anode layer comprising a second projection, a solid-state electrolyte layer intermediate the cathode layer and the anode layer, the solid-state electrolyte layer comprising a first recess complementary to the first projection and a second recess complementary to the second projection, and a second current collector layer deposited over the anode layer.

17 . The system of claim 16 , wherein the cathode layer comprises a plurality of projections.

18 . The system of claim 17 , wherein the solid-state electrolyte layer comprises a plurality of recesses complementary to the projections of the cathode layer.

19 . The system of claim 16 , wherein the anode layer comprises a plurality of projections.

20 . The system of claim 16 , wherein the solid-state electrolyte layer comprises a plurality of recesses complementary to the projections of the anode layer.

21 . The system of claim 16 , wherein the downhole device is coupled to a tool string.