Three-dimensional batteries and methods of manufacturing the same

摘要

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.

主权项

1. A three-dimensional non-aqueous battery, comprising:
a battery enclosure; a first structural layer within the battery enclosure, the first structural layer having a planar surface; a first plurality of conductive protrusions directly connected to and extending at least about 50 microns in a first direction from the planar surface of the first structural layer and having an aspect ratio of approximately 2.5:1 to 500:1; 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 directly connected to and in electrical contact with an outer surface of one of said first plurality of conductive protrusions, the first plurality of cathodes having a thickness of 5 to 200 microns; 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.