Method of fabricating and method of using porous wafer battery

1. A fabrication method of fabricating a porous wafer battery, the fabrication method comprising the steps of:

providing a silicon wafer comprising

a first side;

a second side opposite the first side; and

a plurality of pores, the plurality of pores being through holes extending from the first side of the silicon wafer to the second side of the silicon wafer;

applying a first metallization process so that a first respective metal section of a first plurality of metal sections covers a portion of side walls of each pore of the plurality of pores and a portion of side walls of an adjacent pore of each pore of the plurality of pores;

applying a passivation process forming a plurality of passivation sections;

applying a respective solder ball of a plurality of solder balls at each pore of the plurality of pores;

aligning the silicon wafer with a substrate comprising a plurality of contact bumps; and

applying a solder reflow process so that a respective contact bump of the plurality of contact bumps is attached to each solder ball of the plurality of solder balls.

2. The fabrication method of claim 1 , wherein the first plurality of metal sections contains copper.

3. The fabrication method of claim 1 further comprising, after the step of applying the first metallization process and before the step of applying the passivation process, applying a second metallization process so that a second respective metal section of a second plurality of metal sections covers the first respective metal section.

4. The fabrication method of claim 3 , wherein the first plurality of metal sections contains titanium; and wherein the second plurality of metal sections contains copper.

5. The fabrication method of claim 1 , wherein a majority portion of the respective solder ball is in each pore of the plurality of pores; and wherein a minority portion of the respective solder ball is out of each pore of the plurality of pores.

6. The fabrication method of claim 5 , wherein a diameter of each solder ball of the plurality of solder balls is less than fifty microns.

7. The fabrication method of claim 1 , wherein each of the plurality of passivation sections is of a letter U shape.

8. The fabrication method of claim 7 , wherein a first leg of the letter U shape is directly attached to the first respective metal section of a first selected pore of the plurality of pores; wherein a second leg of the letter U shape is directly attached to the first respective metal section of a second selected pore of the plurality of pores; and wherein the first selected pore is different from the second selected pore.

9. A usage method using a first silicon wafer and a second silicon wafer made by the fabrication method of claim 1 ,

wherein the first silicon wafer is served as an anode and the second silicon wafer is served as a cathode.

10. A usage method using a first silicon wafer made by the fabrication method of claim 1 , the usage method comprising the steps of

forming a respective anode in each pore of the plurality of pores;

forming a respective cathode in each pore of the plurality of pores;

connecting the first silicon wafer to a plurality of sensors;

connecting the first silicon wafer to a plurality of switches; and

connecting the plurality of sensors and the plurality of switches to a battery management system.

11. The usage method of claim 10 further comprising the steps of monitoring a respective temperature of each pore of the plurality of pores; and

electrically disconnecting a selected pore by turning off a respective switch if the respective temperature of the selected pore is larger than a predetermined value.

12. The usage method of claim 10 further comprising the steps of monitoring a respective resistance of each pore of the plurality of pores; and

electrically disconnecting a selected pore by turning off a respective switch if the respective resistance of the selected pore is smaller than a predetermined value.

13. The usage method of claim 10 further comprising the steps of

monitoring respective current of each pore of the plurality of pores;

electrically disconnecting a selected array of pores by turning off respective switches if the respective current of at least one pore of the selected array of pores is smaller than a predetermined value;

curing the at least one pore of the selected array of pores; and

electrically reconnecting the selected array of pores by turning on the respective switches.

14. A usage method using a plurality of silicon wafers made by the fabrication method of claim 1 , the usage method comprising the steps of

forming the plurality of silicon wafers as a stacked porous battery;

forming a plurality of anodes and a plurality of cathodes in the plurality of silicon wafers;

connecting the plurality of silicon wafers to a plurality of sensors;

connecting the plurality of silicon wafers to a plurality of switches; and

connecting the plurality of sensors and the plurality of switches to a battery management system.

15. The usage method of claim 14 further comprising the steps of

monitoring respective current of each silicon wafer of the plurality of silicon wafers;

electrically disconnecting a selected silicon wafer by turning off a respective switch if the respective current of the selected silicon wafer is smaller than a predetermined value;

curing the selected silicon wafer; and

electrically reconnecting the selected silicon wafer by turning on the respective switch.