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 method and system for designing a manufacturing facility for solid state thin film battery devices. The method can include providing a plurality of processing tools for arrangement within a predetermined spatial region of one or more manufacturing facilities. A plurality of variables can be assigned for the plurality of processing tools. A target financial variable can be defined to evaluate different manufacturing processing tool configurations. The plurality of variables in the tensor relationship can be processed to reduce a magnitude of the target variable. An optimized set of the plurality of processing tools and respective configuration with the plurality of tools associated with the reduced magnitude of the target variable can be determined through processing. The optimized set of the plurality of processing tools in the respective configuration can be used in the one or more manufacturing facilities for the manufacture of a solid state thin film battery device.

Abstract: A method and system for designing a manufacturing facility for solid state thin film battery devices. The method can include providing a plurality of processing tools for arrangement within a predetermined spatial region of one or more manufacturing facilities. A plurality of variables can be assigned for the plurality of processing tools. A target financial variable can be defined to evaluate different manufacturing processing tool configurations. The plurality of variables in the tensor relationship can be processed to reduce a magnitude of the target variable. An optimized set of the plurality of processing tools and respective configuration with the plurality of tools associated with the reduced magnitude of the target variable can be determined through processing. The optimized set of the plurality of processing tools in the respective configuration can be used in the one or more manufacturing facilities for the manufacture of a solid state thin film battery device.

Abstract: A method of designing and manufacturing a solid-state electrochemical battery cell for a battery device. The method includes building a database of a plurality of first characteristics of a solid-state cells for a battery device and determining at least a third characteristic of the solid-state cell for a given application. The method also includes selecting at least one material of the solid-state electrochemical battery cell, the selected material being from the plurality of first characteristics and forming a plurality of factorial combinations of each component using the selected plurality of first characteristics to derive a respective plurality of solid-state electrochemical battery cells. The method performs a design optimization process for the third characteristic. A step of identifying an optimal design of the second characteristics with the selected first characteristics for each solid-state electrochemical battery cell from the plurality of solid-state cells is included.

Abstract: A method of the present invention using a prediction process including a battery equivalent circuit model used to predict a voltage and a state of charge of a battery. The equivalent circuit battery model includes different equivalent circuit models consisting of at least an ideal DC power source, internal resistance, and an arbitrary number of representative parallel resistors and capacitors. These parameters are obtained a priori by fitting the equivalent circuit model to battery testing data. The present invention further uses a correction process includes determining a corrected predicted state of charge of the battery; and storing the corrected state of charge of the battery in a storage medium. In the present invention, an expectation of the predicted voltage of the battery and an expectation of the predicted state of charge of the battery are obtained by an unscented transform with sigma points selected by a Gaussian process optimization.

Abstract: A method of determining at least one material property of at least one component of an electrochemical system (fully or partially completed) using a process to reduce a difference of a performance characteristic between a numerical simulation result of a physical model and an empirical result. The method includes providing an electrochemical cell using a thin film process and performing a plurality of tests on the electrochemical cell to identify one or more target performance characteristics of the electrochemical cell. The method includes performing a surrogate based analysis process and determining a plurality of outputs of the surrogate based analysis function and determines a value of the unknown material property.

Abstract: A method and system for designing a manufacturing facility for solid state thin film battery devices. The method can include providing a plurality of processing tools for arrangement within a predetermined spatial region of one or more manufacturing facilities. A plurality of variables can be assigned for the plurality of processing tools. A target financial variable can be defined to evaluate different manufacturing processing tool configurations. The plurality of variables in the tensor relationship can be processed to reduce a magnitude of the target variable. An optimized set of the plurality of processing tools and respective configuration with the plurality of tools associated with the reduced magnitude of the target variable can be determined through processing. The optimized set of the plurality of processing tools in the respective configuration can be used in the one or more manufacturing facilities for the manufacture of a solid state thin film battery device.

Abstract: A method of determining at least one material property of at least one component of an electrochemical system (fully or partially completed) using a process to reduce a difference of a performance characteristic between a numerical simulation result of a physical model and an empirical result. The method includes providing an electrochemical cell using a thin film process and performing a plurality of tests on the electrochemical cell to identify one or more target performance characteristics of the electrochemical cell. The method includes performing a surrogate based analysis process and determining a plurality of outputs of the surrogate based analysis function and determines a value of the unknown material property.

Abstract: A method of designing and manufacturing a solid-state electrochemical battery cell for a battery device. The method includes building a database of a plurality of first characteristics of a solid-state cells for a battery device and determining at least a third characteristic of the solid-state cell for a given application. The method also includes selecting at least one material of the solid-state electrochemical battery cell, the selected material being from the plurality of first characteristics and forming a plurality of factorial combinations of each component using the selected plurality of first characteristics to derive a respective plurality of solid-state electrochemical battery cells. The method performs a design optimization process for the third characteristic. A step of identifying an optimal design of the second characteristics with the selected first characteristics for each solid-state electrochemical battery cell from the plurality of solid-state cells is included.

Abstract: A method of the present invention using a prediction process including a battery equivalent circuit model used to predict a voltage and a state of charge of a battery. The equivalent circuit battery model includes different equivalent circuit models consisting of at least an ideal DC power source, internal resistance, and an arbitrary number of representative parallel resistors and capacitors. These parameters are obtained a priori by fitting the equivalent circuit model to battery testing data. The present invention further uses a correction process includes determining a corrected predicted state of charge of the battery; and storing the corrected state of charge of the battery in a storage medium. In the present invention, an expectation of the predicted voltage of the battery and an expectation of the predicted state of charge of the battery are obtained by an unscented transform with sigma points selected by a Gaussian process optimization.