# US 10,770,756 B2 · Method of manufacturing a lithium battery > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,770,756 B2 - Document ID: US10770756B2 - Status: Granted - Kind: B2 - Application number: 16/312,106 - Filed: 2017-06-22 - Published: 2019-08-08 - Granted: 2020-09-08 - Earliest claimed: 2016-06-23 - Assignees: Nederlandse Organisatie voor toegepast-natuurwetenschappelijk onderzoek TNO - Applicants: Nederlandse Organisatie voor toegepast-natuurwetenschappelijk onderzoek TNO - Inventors: Lucas Augustinus Haverkate; Sandeep Unnikrishnan; Dorothee Christine Hermes - Web page: https://patentgrep.com/patent/US10770756B2 ## CPC - H01M 10/058: Construction or manufacture - H01M 4/045: {Electrochemical coating; Electrochemical impregnation} - H01M 4/0452: {from solutions} - H01M 4/134: Electrodes based on metals, Si or alloys - H01M 4/1395: of electrodes based on metals, Si or alloys - H01M 4/366: {as layered products} - H01M 4/382: {Lithium (H01M4/405 takes precedence)} - H01M 4/661: {Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence)} - H01M 4/70: characterised by shape or form - H01M 4/75: Wires, rods or strips - H01M 10/0413: {Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes} - H01M 10/0436: {Small-sized flat cells or batteries for portable equipment} - H01M 10/052: Li-accumulators - H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries - H01M 10/0562: Solid materials - H01M 10/0585: of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - Y02T 10/70: Energy storage systems for electromobility, e.g. batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A method of manufacturing a battery with a substrate current collector, wherein the method comprises: forming elongate and aligned electrically conductive structures on the substrate face with upstanding walls; wherein the walls are formed with a first electrode layer covering said walls, and a solid state electrolyte layer provided on the first electrode layer; and wherein a second electrode layer is formed by covering the electrolyte layer with an electrode layer; and forming a top current collector layer in electrical contact with the second electrode layer, wherein the second electrode layer is shielded from the conductive structure by an insulator covering a part of said conductive structure adjacent an end side thereof. ## Claims ### Claim 1 A method of manufacturing a battery with a substrate current collector, wherein the method comprises: forming an elongate and aligned electrically conductive structures on a substrate face with the electrically conductive structures having upstanding walls in relation to the substrate face; wherein the upstanding walls are formed with a first electrode layer covering said upstanding walls, a solid state electrolyte layer is provided on the first electrode layer; and wherein a second electrode is formed by covering the solid state electrolyte layer; and forming a top current collector layer in electrical contact with the second electrode, wherein the second electrode is shielded from the electrically conductive structures by an insulator covering a part of the electrically conductive structures adjacent an end side the electrically conductive structures to prevent an ion transport path between the first electrode layer and the second electrode, thereby mitigating stress build up near the end side of the electrically conductive structures. ### Claim 2 (depends on 1) A method according to claim 1, wherein the top current collector aye is formed on top of the electrically conductive structures on the substrate face. ### Claim 3 (depends on 1) A method according to claim 1, wherein the top current collector layer is provided at the base of the electrically conductive structures with the insulator shielding the top current collector from the substrate current collector. ### Claim 4 (depends on 1) A method according to claim 1, wherein the insulator partly covers the first electrode layer. ### Claim 5 (depends on 1) A method according to claim 1, wherein the second electrode is a Lithium metal layer. ### Claim 6 (depends on 5) A method according to claim 5 wherein the Lithium metal layer is provided by depositing a seed layer on the solid state electrolyte layer, and plating the seed layer in a metal plating process with a Lithium metal. ### Claim 7 (depends on 6) A method according to claim 6, wherein the plating comprises extracting the Lithium metal from the first electrode layer by providing an electrical voltage difference between the electrically conductive structures, which form metal pillars, and the seed layer. ### Claim 8 (depends on 6) A method according to claim 6, wherein the plating comprises providing an electrical voltage difference between the seed layer and a counter electrode that is separated from the seed layer; wherein the counter electrode and/or an electrolyte in contact with the seed layer comprise a Lithium source. ### Claim 9 (depends on 1) A method according to claim 1, wherein the top current collector layer extends along the upstanding walls. ### Claim 10 (depends on 1) A method according to claim 1, wherein an interspace structure is provided separating adjacent ones of the electrically conductive structures so that the second electrode extends into the interspace structure, wherein said interspace structure comprises an electroconductive scaffold. ### Claim 11 (depends on 10) A method according to claim 10, wherein the electroconductive scaffold is formed by a hollow or porous metal structure. ### Claim 12 (depends on 10) A method according to claim 10, wherein the electroconductive scaffold is formed of conductive nanoparticles. ### Claim 13 (depends on 1) A method according to claim 1, wherein an interspace structure is provided separating adjacent ones of the electrically conductive structures so that the second electrode extends into the interspace structure, wherein said interspace structure comprises a compression layer, that conforms to the second electrode, said compression layer being provided when the second electrode is Lithium that is depleted. ### Claim 14 (depends on 1) A method according to claim 1, wherein an interspace structure between ones of the electrically conductive structures comprises a compression layer, that conforms to the second electrode, said compression layer comprising a Lithium ion conductive material to provide the second electrode. ### Claim 15 A battery with a substrate current collector, wherein the substrate current collector comprises elongate and aligned electrically conductive structures, on a substrate face of a substrate, with upstanding walls; wherein the upstanding walls are formed with a first electrode layer covering said upstanding walls, a solid state electrolyte layer is provided on the first electrode layer; and wherein a second electrode is formed by covering the solid state electrolyte layer; and wherein a top current collector layer is in electrical contact with the second electrode, wherein the second electrode is shielded from the electrically conductive structures by an insulator covering a part of the electrically conductive structures adjacent an end side of the electrically conductive structure to prevent an ion transport path between the first electrode layer and the second electrode, thereby mitigating stress build up near the end side of the electrically conductive structures. ### Claim 16 (depends on 15) The battery according to claim 15 wherein the electrically conductive structures comprise high-aspect ratio electrically conductive pillar structures having a radius of curvature larger than 50 nanometer. ### Claim 17 (depends on 16) The battery according to claim 16, wherein the pillar structures are higher than 10 micrometer. ### Claim 18 (depends on 15) The battery according to claim 15, wherein the substrate is a metal foil having both faces forming a high-aspect ratio structure. ### Claim 19 (depends on 15) The battery according to claim 15, having a plurality of current collectors, that are stacked in parallel or stacked in series. ### Claim 20 (depends on 15) The battery according to claim 15, wherein the substrate is a metal layer stacked on an organic foil.