Three-dimensional batteries and methods of manufacturing the same
Various methods and apparatus relating to three-dimensional battery structures and methods of manufacturing them are disclosed and claimed. In certain embodiments, a three-dimensional battery comprises a battery enclosure, and a first structural layer within the battery enclosure, where the first structural layer has a first surface, and a first plurality of conductive protrusions extend from the first surface. A first plurality of electrodes is located within the battery enclosure, where the first plurality of electrodes includes a plurality of cathodes and a plurality of anodes, and wherein the first plurality of electrodes includes a second plurality of electrodes selected from the first plurality of electrodes, each of the second plurality of electrodes being in contact with the outer surface of one of said first plurality of conductive protrusions. Some embodiments relate to processes of manufacturing energy storage devices with or without the use of a backbone structure or layer.
1. A three-dimensional battery, comprising:
a battery enclosure;
a first structural layer within the battery enclosure, said structural layer having a first surface;
a first plurality of conductive protrusions connected to and extending at least about 50 microns in a first direction from said first surface of said first structural layer and having an aspect ratio of approximately 2.5:1 to 500:1; and
a first plurality of cathodes and a first plurality of anodes within the battery enclosure, each of the first plurality of cathodes and first plurality of anodes being connected to and in electrical contact with an outer surface of one of said first plurality of conductive protrusions; and
a porous separator material between the first plurality of cathodes and the first plurality of anodes, whereby the first plurality of cathodes are in ionic connection to the first plurality of anodes through the porous separator material.
2. The three-dimensional battery of claim 1 , further comprising:
a second structural layer within the battery enclosure, said second structural layer having a second surface;
a second plurality of conductive protrusions extending from said second surface of said second structural layer; and
a second plurality of electrodes selected from the first plurality of electrodes, each of the second plurality of electrodes being in contact with the outer surface of one of said second plurality of conductive protrusions.
3. The three-dimensional battery of claim 2 , the second plurality of electrodes consisting of a plurality of anodes.
4. The three-dimensional battery of claim 2 , the second plurality of electrodes consisting of a plurality of cathodes.
5. The three-dimensional battery of claim 1 , wherein at least a portion of said first plurality of conductive protrusions surround a base material protruding from said first surface of said first structural layer.
6. The three-dimensional battery of claim 5 , wherein said base material and said first structural layer comprise the same material.
7. The three-dimensional battery of claim 1 , wherein each of said first plurality of anodes comprises a layer overlying the outer surface of one of said first plurality of conductive protrusions.
8. The three-dimensional battery of claim 1 , wherein said first plurality of conductive protrusions comprise fins protruding at least 50 microns from said first structural layer and having a thickness smaller than 20 microns.
9. The three-dimensional battery of claim 1 , wherein said first plurality of conductive protrusions comprise pillars protruding at least 50 microns from said first structural layer.
10. The three-dimensional battery of claim 1 , wherein each of said first plurality of cathodes comprises a layer overlying the outer surface of one of said first plurality of conductive protrusions.
11. The three-dimensional battery of claim 1 , wherein said first plurality of conductive protrusions comprise fins protruding at least 50 microns from said first structural layer and having a thickness smaller than 20 microns.
12. The three-dimensional battery of claim 1 , wherein said first plurality of conductive protrusions comprise pillars protruding at least 50 microns from said first structural layer.
13. The three-dimensional battery of claim 12 , each of said pillars being substantially cylindrical.
14. The three-dimensional battery of claim 2 , wherein said first plurality of conductive protrusions is electrically insulated from said second plurality of conductive protrusions.
15. The three-dimensional battery of claim 1 wherein each of the first plurality of anodes each has a thickness of 5 to 200 μM.
16. The three-dimensional battery of claim 1 wherein each of the first plurality of anodes has a thickness of 10 to 150 μM.
17. The three-dimensional battery of claim 1 wherein each of the first plurality of cathodes has a thickness of 10 to 150 μM.
18. The three-dimensional battery of claim 1 wherein each of the first plurality of anodes has a thickness of 10 to 150 μM and each of the first plurality of cathodes has a thickness of 10 to 150 μM.
19. The three-dimensional battery of claim 1 wherein each of the first plurality of anodes comprises tin, silicon, or aluminum, or is a titanate.
20. The three-dimensional battery of claim 1 wherein each of the first plurality of anodes comprises carbon.
21. The three-dimensional battery of claim 1 wherein each of the first plurality of anodes has a thickness of 5 to 200 μM.
22. The three-dimensional battery of claim 1 wherein each of the first plurality of anodes has a thickness of 10 to 150 μM.
23. The three-dimensional battery of claim 1 , wherein each of the first plurality of conductive protrusions that is contacted by one of the first plurality of cathodes is discontinuous from each of the first plurality of conductive protrusions that is contacted by one of the first plurality of anodes.