Abstract: A method for manufacturing a solid-state battery device. The method can include providing a substrate within a process region of an apparatus. A cathode source and an anode source can be subjected to one or more energy sources to transfer thermal energy into a portion of the source materials to evaporate into a vapor phase. An ionic species from an ion source can be introduced and a thickness of solid-state battery materials can be formed overlying the surface region by interacting the gaseous species derived from the plurality of electrons and the ionic species. During formation of the thickness of the solid-state battery materials, the surface region can be maintained in a vacuum environment from about 10?6 to 10?4 Torr. Active materials comprising cathode, electrolyte, and anode with non-reactive species can be deposited for the formation of modified modulus layers, such a void or voided porous like materials.

Abstract: A thin film solid state battery configured with barrier regions formed on a flexible substrate member and method. The method includes forming a bottom thin film barrier material overlying and directly contacting a surface region of a substrate. A first current collector region can be formed overlying the bottom barrier material and forming a first cathode material overlying the first current collector region. A first electrolyte can be formed overlying the first cathode material, and a second current collector region can be formed overlying the first anode material. The method also includes forming an intermediary thin film barrier material overlying the second current collector region and forming a top thin film barrier material overlying the second electrochemical cell. The solid state battery can comprise the elements described in the method of fabrication.

Abstract: A thin film solid state battery configured with barrier regions formed on a flexible substrate member and method. The method includes forming a bottom thin film barrier material overlying and directly contacting a surface region of a substrate. A first current collector region can be formed overlying the bottom barrier material and forming a first cathode material overlying the first current collector region. A first electrolyte can be formed overlying the first cathode material, and a second current collector region can be formed overlying the first anode material. The method also includes forming an intermediary thin film barrier material overlying the second current collector region and forming a top thin film barrier material overlying the second electrochemical cell. The solid state battery can comprise the elements described in the method of fabrication.

Abstract: A method for fabricating a solid state battery device. The device can include electrochemically active layers and an overlaying barrier material, with an inter-digitated layer structure configured with a post terminated lead structure. The method can include forming a plurality of battery device cell regions (1-N) formed in a multi-stacked configuration, wherein each of the battery device cell regions comprises a first current collector and a second current collector. The method can also include forming a thickness of a first and second lead material to cause formation of a first and second lead structure to interconnect each of the first and second current collectors associated with each of the plurality of battery device cell regions and to isolate each of the second current collectors extending spatially outside of the battery device cell region within a first and second isolated region, respectively.

Abstract: A monolithically integrated thin-film solid-state lithium battery device to supply energy to a mobile communication device. The battery device comprises multiple layers ranging from greater than 100 layers to less than 20,000 layers of lithium electrochemical cells. The lithium electrochemical cells are connected in parallel or in series to conform to a spatial volume. The device is substantially free from a substrate member. The overlying multiple layers are free from any intermediary substrate member. The multiple layers are configured to form a plurality of electrochemical cells configured in a parallel arrangement or a serial arrangement using either a self terminated or post terminated connector configuration.

Abstract: A high speed deposition apparatus for the manufacture of solid state batteries. The apparatus can be used for the manufacture of solid state multilayer stacked battery devices via a vacuum deposition process. In various embodiments, the manufacturing apparatus can include a containment vessel, a reactor region, a process region, a work piece, one or more vacuum chambers, and an energy source. A complete stack of battery layers can be manufactured in a single vacuum cycle, having background gas, pressure, and deposition rate optimized and controlled for the deposition of each layer. The work piece can include a drum and a substrate, which can be a commercial polymer or metallic web, that are temperature controlled. Masks can be used to delineate or shape layers within the multi-layer stacked electrochemical device manufactured by embodiments of the apparatus.

Abstract: A method of producing a monolithically integrated high energy density solid-state battery device. The method can include positioning a substrate and depositing one or more stacked monolithically integrated high energy density solid-state electrochemical cells in series or in parallel configurations sequentially or individually. Each of these cells can have a first barrier layer, a cathode current collector deposited overlying the first barrier layer, a cathode overlying the electrically conductive layer, an anode, an anode current collector deposited overlying the solid state layer of negative electrode material, and a second barrier layer.

Abstract: A method of fabricating a multilayered thin film solid state battery device. The method steps include, but are not limited to, the forming of the following layers: substrate member, a barrier material, a first electrode material, a thickness of cathode material, an electrolyte, an anode material, and a second electrode material. The formation of the barrier material can include forming a polymer material being configured to substantially block a migration of an active metal species to the substrate member, and being characterized by a barrier degrading temperature. The formation of cathode material can include forming a cathode material having an amorphous characteristic, while maintaining a temperature of about ?40 Degrees Celsius to no greater than 500 Degrees Celsius such that a spatial volume is characterized by an external border region of the cathode material. The method can then involve transferring the resulting thin film solid state battery device.

Abstract: A pulsed laser can be used to ablate the desired thin film layers at a desired location, to a desired depth, without impinging significantly upon other layers. The battery cell layer order may be optionally optimized to aid in ease of laser ablation. The laser process can isolate layers of thin film within sufficient proximity to at least one edge of the final thin film battery stack to optimize active battery area.

Abstract: Elements of an electrochemical cell using an end to end process. The method includes depositing a planarization layer, which manufactures embedded conductors of said cell, allowing a deposited termination of optimized electrical performance and energy density. The present invention covers the technique of embedding the conductors and active layers in a planarized matrix of PML or other material, cutting them into discrete batteries, etching the planarization material to expose the current collectors and terminating them in a post vacuum deposition step.

Abstract: A multi-layered solid-state battery device can have a substrate member having a surface region and a thin film battery device layer overlying the barrier material. The thin film battery device layer can comprise a cathode current collector, a cathode device, an electrolyte, an anode device, and an anode current collector. The device can have a non-planar surface region configured from the thin film battery device and a first polymer material overlying the thin film battery device and configured to fill in a gap region of the non-planar surface region and a planarizing surface region configured from the first polymer material.

Abstract: A method and apparatus for manufacturing electrochemical cells. The apparatus and method includes the modification of solid phase material used in electrochemical cells, such as batteries, into a viscous phase for ease of metering and dispensing onto a hot wall reactor to create a substantially uniform cloud of vapor to be deposited on a substrate or other stacks of cells in a continuous or semi-continuous process and having the useful advantage of depositing large volumes of materials for economical manufacturing.

Abstract: Disclosed are systems that include a plurality of solid state rechargeable battery cells. The system can be configured to power a drivetrain and can include a rolled substrate and at least one electrochemical cell overlying the surface region of the rolled substrate. The electrochemical cell can include a positive electrode, a solid state layer, a negative electrode, and an electrically conductive material.

Abstract: A method for the continuous or semi-batch manufacture of a solid-state battery device using a high speed process. The method can include forming multiple repeating stacks of thin film layers overlying a substrate in order to form multiple solid state batteries connected in series or parallel, wherein forming the multiple repeating stacks of thin film layers includes forming a polymer interlayer. The method can also include stacking multiple stacks of thin film layers of multi-layer battery cells connected in parallel or in series.

Abstract: A multi-layered solid-state battery device can have a substrate member having a surface region and a thin film battery device layer overlying the barrier material. The thin film battery device layer can comprise a cathode current collector, a cathode device, an electrolyte, an anode device, and an anode current collector. The device can have a non-planar surface region configured from the thin film battery device and a first polymer material overlying the thin film battery device and configured to fill in a gap region of the non-planar surface region and a planarizing surface region configured from the first polymer material.

Abstract: An integrated energy storage system can include a first, second, and third energy storage units and a controller. The first energy storage units can have a gravimetric energy density of greater than 180 Wh/kg and volumetric energy density greater than 450 Wh/L in an environmental temperature above 0° C., the second energy storage units can have a gravimetric power density of greater than 450 W/kg and volumetric power density greater than 1080 W/L in an environmental temperature above 0° C., and the third energy storage units can be configured to operate in an environmental temperature as low as ?100° C. The controller can be programmed to receive inputs from voltage sensors, current sensors, and temperature sensors, and to allocate the current or power among the first, second, or third energy storage units depending on a power consumption from an application load and an environmental temperature.

Abstract: A high speed deposition apparatus for the manufacture of solid state batteries. The apparatus can be used for the manufacture of solid state multilayer stacked battery devices via a vacuum deposition process. In various embodiments, the manufacturing apparatus can include a containment vessel, a reactor region, a process region, a work piece, one or more vacuum chambers, and an energy source. A complete stack of battery layers can be manufactured in a single vacuum cycle, having background gas, pressure, and deposition rate optimized and controlled for the deposition of each layer. The work piece can include a drum and a substrate, which can be a commercial polymer or metallic web, that are temperature controlled. Masks can be used to delineate or shape layers within the multi-layer stacked electrochemical device manufactured by embodiments of the apparatus.

Abstract: A method of producing a monolithically integrated high energy density solid-state battery device. The method can include positioning a substrate and depositing one or more stacked monolithically integrated high energy density solid-state electrochemical cells in series or in parallel configurations sequentially or individually. Each of these cells can have a first barrier layer, a cathode current collector deposited overlying the first barrier layer, a cathode overlying the electrically conductive layer, an anode, an anode current collector deposited overlying the solid state layer of negative electrode material, and a second barrier layer.

Abstract: A pulsed laser can be used to ablate the desired thin film layers at a desired location, to a desired depth, without impinging significantly upon other layers. The battery cell layer order may be optionally optimized to aid in ease of laser ablation. The laser process can isolate layers of thin film within sufficient proximity to at least one edge of the final thin film battery stack to optimize active battery area.

Abstract: A thin film solid state battery configured with barrier regions formed on a flexible substrate member and method. The method includes forming a bottom thin film barrier material overlying and directly contacting a surface region of a substrate. A first current collector region can be formed overlying the bottom barrier material and forming a first cathode material overlying the first current collector region. A first electrolyte can be formed overlying the first cathode material, and a second current collector region can be formed overlying the first anode material. The method also includes forming an intermediary thin film barrier material overlying the second current collector region and forming a top thin film barrier material overlying the second electrochemical cell. The solid state battery can comprise the elements described in the method of fabrication.