Thin film batteries comprising a glass or ceramic substrate

• US 10,020,540 B2
• Filed: 10/15/2013
• Issued: 07/10/2018
• Est. Priority Date: 10/15/2012
• Status: Active Grant

• Current Assignee: Cymbet Corporation
• Original Assignee: Cymbet Corporation
• Inventors: Shakespeare, Stuart Kevin, Stanislowski, Stanley Jacob, Flatland, Matthew E., Downey, Stephen W., Thoma, Morgan J.
• Primary Examiner(s): RAYMOND, BRITTANY L
• Application Number:
  US14/434,700
• Publication Number:
  US 20150280284A1
• Time in Patent Office: 1,729 Days
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0562 Solid materials
• CPC Class Codes: H01M 10/0585 of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 2300/0068 inorganic
• CPC Class Codes: H01M 4/0471 involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
• CPC Class Codes: H01M 4/1391 of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1397 of electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
• CPC Class Codes: H01M 4/505 of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
• CPC Class Codes: H01M 4/525 of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• CPC Class Codes: H01M 4/5825 Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
• CPC Class Codes: H01M 4/66 Selection of materials
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 6/186 Only oxysalts-containing solid electrolytes
• CPC Class Codes: H01M 6/188 Processes of manufacture
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A thin film battery comprises a glass or ceramic substrate having a coefficient of thermal expansion (“CTE”) of from about 7 to about 10 ppm/° K, a continuous metal or metal oxide cathode current collector and having a thickness of less than about 3 micrometers, the cathode current collector being superjacent to the glass or ceramic substrate, a cathode material layer comprising lithium transition metal oxides that is a continuous film having a thickness of from about 10 to about 80 micrometers, the cathode material layer being superjacent to the cathode current collector, a LiPON electrolyte layer superjacent to the cathode material layer and having a thickness of from about 0.5 to about 4 micrometers, and an anode current collector with an optional anode material. Methods of making and using the batteries are described.

Claims

1. A thin film battery comprising:

a) a glass substrate having a CTE of from about 7 to about 10 ppm/°

K;

b) a continuous metal or metal oxide cathode current collector having a thickness of less than about 3 micrometers, the cathode current collector being superjacent to the glass substrate;

c) a cathode material layer comprising lithium transition metal oxides that is a continuous film having a thickness of from about 10 to about 80 micrometers, the cathode material layer being superjacent to the cathode current collector;

d) a LiPON electrolyte layer having a thickness of from about 0.5 to about 4 micrometers, the LiPON electrolyte layer being superjacent to the cathode material layer micrometer; and

e) an anode current collector.

2. The thin film battery of claim 1, wherein the glass substrate is the only substrate material in the battery.

3. The thin film battery of claim 1, wherein the glass substrate has a thickness of from about 20 to about 50 micrometers.

4. The thin film battery of claim 1, wherein the cathode material layer comprises lithium transition metal oxides selected from the group consisting of LiCoO₂, LiFePO₄, LiMnO₂, LiNi_1/3Mn_1/3CO_1/3O₂ and mixtures thereof.

5. The thin film battery of claim 1, wherein the only lithium transition metal oxide in the cathode material layer is LiCoO₂.

6. The thin film battery of claim 1, wherein the cathode material layer has a thickness of from about 15 to about 50 micrometers.

7. The thin film battery of claim 1, wherein the cathode material layer has been annealed to a temperature of from about 500°

C. to about 800°

C.

8. The thin film battery of claim 1, wherein the cathode material layer has been annealed to a temperature of from about 650°

C. to about 750°

C.

9. The thin film battery of claim 1, wherein the metal or metal oxide cathode current collector is selected from the group consisting of copper, aluminum, nickel, iron, gold, silver, platinum, molybdenum, titanium, manganese, indium, metal alloys, oxides and combinations thereof.

10. The thin film battery of claim 1, wherein the metal or metal oxide cathode current collector metal or has a CTE of from about 6 to about 12 ppm/°

K.

11. The thin film battery of claim 1, wherein the metal or metal oxide cathode current collector metal or has a CTE of from about 7 to about 10 ppm/°

K.

12. The thin film battery of claim 1, wherein the metal or metal oxide cathode current collector is indium tin oxide.

13. The thin film battery of claim 1, wherein the metal or metal oxide cathode current collector is platinum.

14. The thin film battery of claim 1, wherein the metal or metal oxide cathode current collector is aluminum.

15. The thin film battery of claim 1, wherein the battery further comprises an anode.

16. The thin film battery of claim 1, wherein the glass substrate has two major surfaces, and wherein a battery cell array is present on both major surfaces of the glass substrate.

17. The thin film battery of claim 16, wherein the battery cell array provides a lifecycle capacity of from about 0.5 mAh to about 500 mAh.

18. The thin film battery of claim 16, wherein the battery cell array provides a lifecycle capacity of from about 5 mAh to about 100 mAh.

19. The thin film battery of claim 1, wherein the glass substrate comprises a metal oxide selected from silicon, aluminum, boron, sodium, potassium, calcium, magnesium, zinc, manganese and cobalt oxides.

20. The thin film battery of claim 1, wherein the battery provides a lifecycle capacity of from about 0.5 mAh to about 20 mAh.