Ultra-Thin, Solid-State Rechargeable Battery with Vertically Integrated Solar Cell

Transcription

1 Ultra-Thin, Solid-State Rechargeable Battery with Vertically Integrated Solar Cell B.S. Berland, C. Sprangers, A. Compaan, V. Plotnikov, D. Carey, K. Olenick, J. Olenick Brian Berland Chief Science Officer ITN Energy Systems, Inc. Thank You for Support From:

2 Need: Ultra-Thin, Flexible Power Sources Wearables, Flex Electronics, Sensors/IoT, are Limited by the Battery Size and Energy Density 3d-prints-functional-circuits-using-new-eoprom-solution.html

3 Battery Energy Density is Increasing Over Time..But Not for Ultra-Thin Batteries Wanxiang A123 Li-Tec Samsung Pouch Daimler Fiat BMW 247 Wh/l 316 Wh/l 243 Wh/l Panasonic LG Samsung NCR18650GA INR18650-MJ1 INR E 697 Wh/l 726 Wh/l 714 Wh/l Ultra-Thin Batteries (<500 mm thick) Energy Density ~ Wh/l <0.7 Wh/l-mm package thickness * *Source:

4 Thin Flexible Power Source (TFPS) Development Project Goal*: Ultra-Thin Flexible Power Sources (TFPS) for Flexible Electronic Print (FEP) Devices, Minimize Footprint, i.e. 2 x 3 x 0.01 <250 mm Total Packaged Thickness *Projects sponsored by the FlexTech Alliance Thin Flexible Power Source Based on SSLB (Sept 2016-Feb 2018) Flexible Integrated Power Pack Integrating CdTe PV with SSLB (Aug 2017-July 2018

5 Solid State Lithium Batteries (SSLB) Ultra-Thin, Flexible, High Energy Density, Safe, Rechargeable Battery Solid State Materials Simplify Packaging YSZ Substrates 20 mm Thick, or less, Supports High Energy Density >1,000 Wh/l Supports High Current Pulses Required for Flexible Electronic Print Devices Capacity 20 mah to >100 mah in a Package less than 250 mm Thick (2 x3 ) Family of SSLB using a Strategy of Standard Materials and Process with Custom Designs based on Application Requirements

6 SSLB Demonstrated on 20 mm YSZ Substrate Feasibility Established for SSLB Cells on 20 mm YSZ Substrates Area up to 100 cm 2 Cathodes 5-15 mm Thick Capacity Scales with Area and Cathode Thickness Adjust to Meet Application Requirements Same Materials and Processes

7 SSLB Cell Integration to Thin, Flexible Power Source (TPFS) Batteries Fabricated by Connecting Multiple SSLB Cells Cells Connected in Parallel SSLB Battery Capacity = Sum of Cell Capacities Cells Discharged at 1 ma (C/4) Battery Discharged at 2 ma (C/4)

8 TFPS Demonstrations Family of TFPS Produced with a Wide Range of Size, Capacity, Thickness End User Can Chose the TFPS that Best Matches Their Requirements 8 mah TFPS 20 mah TFPS 60 mah TFPS 2 cm x 4 cm (8 cm 2 ) 4-Cells Packaged Thickness <200 mm Individual SSLB Cell ~ 2mAh TFPS Battery ~8 mah 3.1 cm x 7.6 cm (24 cm 2 ) 2-Cells Packaged Thickness <100 mm Individual SSLB Cell ~ 9 mah TFPS Battery ~16 mah 6.6 cm x 7.6 cm (50 cm 2 ) 3-Cell Parallel Connection (via External Circuit) Projected Package Thickness <160 mm Individual SSLB Cell ~ 20mAh TFPS Battery ~58 mah

9 TFPS Energy Density 1 st TFPS 2 nd TFPS TFPS Roadmap Substrate Thickness 20 mm 20 mm <12 mm Substrate Area 25 cm 2 50 cm 2 50 cm 2 Battery Thickness <100 mm <150 mm 250 mm Battery Capacity* mah mah 360 mah Energy Density* 480 Wh/l Up to 600 Wh/l >1,000 Wh/l * Projection based on current materials and cell performance * Projection based on anticipated improvement in materials and cell performance

10 SSLB Produced on mm YSZ Substrate Feasibility of Ultra-Thin SSLB Cells has Been Established on mm YSZ Substrates Initial Feasibility with 1 cm 2 SSLB Supports Roadmap to Very High Energy Density Thin Flexible Power Sources (TFPS) Based on SSLB Volumetric Density:>1,000 Wh/l Gravimetric Density: ~250 Wh/kg SSLB on mm YSZ

11 Novel Packaging Validated SSLB Powering Display (embedded movie) Total packaged thickness ~ 100 mm No additional packaging required!

12 Novel Packaging Validated TFPS were Produced and Packaged for Flex2017 Demonstrations 4 cm x 2 cm area, packaged batteries Typical Capacity mah Parts Cycled Several Times Under High Current, Cycled Several Times to Power Demos in Monterey ~4-6 ma Continuous Before Recharge Parts Stored in Ambient for >6 Months After Returning from Show Remain Active with Relatively Stable Capacity WVTR Measured for Packaging Materials 1.3X10-5 g/m 2 -day Translates to <1% Capacity Loss in 5 years Storage Shelf Life ~8-Months Storage in Ambient

13 Boot-Up Backlight On Blue Tooth Communication Initialize, Sensor Read, RF Data Transmit Duty Cycles for Flexible Electronics Devices Often Demand Low Power with Periodic High Current Spikes Fitness Watch Wireless Sensor * * Rest Between Readings Rest *Wireless Sensors for Spacesuit Heath Monitoring (NASA SBIR)

14 SSLB High Current Pulsing >2,500 Pulses 4 mah SSLB Capacity 40 ma = 10 C Rate 3.5 V chosen based on a survey of power down spec from a survey of a few consumer electronic devices 100 millisecond High Current Pulses C/10 Discharge in Between

15 SSLB Powering Flexible Electronics Flexible Electronic Print Device (FEP) Test Case FEP Operating Duration Increased Significantly with SSLB Example ITN SSLB Rechargeable Battery 1.25 x3, <100 mm Thick FEP Baseline (COTS) Primary Battery, 2 x3, >450 mm Thick High Current Spikes Supported Throughout

16 SSLB Powering Flexible Electronics Quick Charging Consistent Powering of FEP Packaged TFPS 2-Cell, 3.1 cm x7.6 cm 50% 75% 90% 100% 15 min 24 min 36 min 64 min 91.9% Retention after 10 cycles (C/2 constant current Rate)

17 SSLB UL Safety Testing (1642) Initial Testing: Pass Short Circuit, Crush Test Short Circuit Test Short Charged Cell; R <0.1 Ohm Track Temperature, Voltage vs time No Fire or Explosion to Pass Test Temperature <45 C Time <1 sec to discharge No Fire or Explosion Crush Test Charged Cell Placed in Mechanical Press 3000 lbs Force Applied No Fire or Explosion to Pass Test No Fire or Explosion ~20 mah SSLB ~1 mah SSLB

18 Flexible Integrated Power Pack (FIPP) Project Goal*: Vertically Integrated Packaged SSLB, PV, Control Electronics Key Features: High efficiency (14%), Thin-film CdTe PV on Ultra-Thin YSZ In-Field SSLB Recharging Superstrate Configuration, i.e. Shared Packaging to Maximize Energy Density Flexible Power Supply Ideal for Flexible Hybrid Electronics 250 mw PV, 60 mah SSLB in a Pack less than 250 mm Thick (1.25 x3 ) *Project sponsored by the FlexTech Alliance (Sept Feb 18, 2018)

19 Flexible Integrated Power Pack (FIPP) Status Feasibility of CdTe PV on YSZ Established* Basic FIPP Functionality Demonstrated Currently >7% Efficiency on YSZ Project Target 14% Has been achieved on other substrates More Details in Next Talk: Ultra-light-weight, thin film CdTe PV minimodules on flexible ceramic- Victor Plotnikov For Example, TFPS Voltage Increase with Solar Charging Si Solar Cell to be Replaced with CdTe in Q FIPP also Powered FEP Load with both SSLB and PV Direct, Provided Over-Discharge Protection to SSLB, Low Power Sleep Mode *Project sponsored by the FlexTech Alliance (Aug 2017-July 2018)

20 FIPP Status FIPP Project Targets Based on 1.25 x 3 x 0.01 Package 1 st FIPP 2 nd FIPP 31 mm 76 mm Substrate Area, FIPP Thickness 25 cm 2, <250 mm PV Efficiency 7% 14% PV Generating Capacity 120 mw 215 mw SSLB Layers, SSLB Capacity Up to 5, Up to 60 mah Charge Time < 2 hours <1.2 hours Aggregate Energy Density (Packaged PV + SSLB) >400 Wh/l * Projection, Current PV performance * Projection, anticipated PV improvements

21 Acknowledgements See ENrG in Booth # 3014