High charge rate, large capacity, solid-state battery

• US 10,644,355 B2
• Filed: 11/20/2017
• Issued: 05/05/2020
• Est. Priority Date: 04/06/2017
• Status: Active Grant

• Current Assignee: International Business Machines Corporation
• Original Assignee: International Business Machines Corporation
• Inventors: de Souza, Joel P., Lee, Yun Seog, Li, Ning, Sadana, Devendra K.
• Primary Examiner(s): McConnell, Wyatt P
• Application Number:
  US15/818,350
• Publication Number:
  US 20180294528A1
• Time in Patent Office: 897 Days
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0463 Cells or batteries with horizontal or inclined electrodes
• CPC Class Codes: H01M 10/0472 Vertically superposed cells with vertically disposed plates
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• 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 2200/103 Fuse
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 50/507 comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules
• CPC Class Codes: H01M 50/54 Connection of several leads or tabs of plate-like electrode stacks, e.g. electrode pole straps or bridges
• CPC Class Codes: H01M 50/583 in response to current, e.g. fuses
• 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

Solid-state battery structures, particularly solid-state lithium-based battery structures, which are fast charging and have a high capacity are provided. Notably, fast charging, high capacity solid-state battery structures are provided that include a plurality of solid-state-thin-film batteries that are stacked one atop the other, or that include an array of interconnected solid-state thin-film batteries, or that contain a solid-state thin-film battery located on physically exposed surfaces of fin structures.

Claims

1. A solid-state battery structure comprising:

a first battery level comprising an array of solid-state thin-film batteries located on a surface of a substrate, a first bus bar located on the substrate and positioned laterally adjacent to each solid-state thin film battery of the array of solid-state thin film batteries, and a fuse element in proximity to each solid-state thin-film battery of the plurality of solid-state thin-film batteries, wherein each fuse element in the first battery level has a first end connected to a sidewall surface of a bottom electrode of one of the solid-state thin-film batteries in the first battery level and a second end connected to a sidewall surface of the first bus bar;

at least one second bus bar entirely spaced apart from the substrate and the first bus bar, wherein the at least one second bus bar has a bottommost surface the directly contacts a topmost surface of a top electrode of of at least one of the solid-state thin-film batteries in the first battery level; and

a second battery level comprising an array of solid-state thin-film batteries located above the at least one second bus bar.

2. The solid-state battery structure of claim 1, further comprising a third battery level located on the second battery level, wherein the third battery level comprises an array of solid-state thin-film batteries and a fuse element in proximity to each solid-state thin-film battery of the plurality of solid-state thin-film batteries in the third battery level, wherein each fuse element in the third battery level has a first end connected to a bottom electrode of one of the solid-state thin-film batteries in the third battery level and a second end connected to a first bus bar present in the third battery level;

and at least one second bus bar located on the third battery level.

3. The solid-state battery structure of claim 2, wherein each bottom electrode of the plurality of solid-state thin-film batteries present in the third battery level is in direct contact with one of the top electrodes within the second battery level, and the bottom electrodes of the plurality of solid-state thin-film batteries present in the third battery level are of the same type as the top electrodes of the plurality of solid-state thin-film batteries present in the second battery level.

4. The solid-state battery structure of claim 1, wherein each solid-state thin-film battery of the array of solid-state thin-film batteries in the first battery level comprises a bottom electrode, a battery cell material stack and a top electrode.

5. The solid-state battery structure of claim 4, wherein the battery cell material stack comprises a cathode and a solid-state electrolyte.

6. The solid-state battery structure of claim 5, wherein the battery cell material stack further comprises an anode region located between the solid-state electrolyte and the top electrode.

7. The solid-state battery structure of claim 6, wherein the battery cell material stack is lithium-based, the cathode comprises a lithium-based mixed oxide, and the solid-state electrolyte comprises a material that enables the conduction of lithium ions.

8. The solid-state battery structure of claim 7, wherein the anode region is composed of a plurality of lithium regions.

9. The solid-state battery structure of claim 7, wherein the anode region comprises a lithium ion generator or a lithium intercalation active material.

10. The solid-state battery structure of claim 1, wherein each fuse element is composed of a metal or metal alloy that melts when the battery is shunted and current is overflowed.

11. The solid-state battery structure of claim 10, wherein the metal or metal alloy is selected from the group consisting of indium, tin, gallium, and their alloys.

12. The solid-state battery structure of claim 1, wherein the at least one second bus bar is a single bus bar.

13. The solid-state battery structure of claim 1, wherein the at least one second bus bar comprises a plurality of spaced apart bus bars.

14. The solid-state battery structure of claim 1, further comprising a porous dielectric material encasing each fuse element.

15. The solid-state battery structure of claim 14, wherein the porous dielectric material is composed of porous carbon.

16. The solid-state battery of claim 1, wherein the fuse elements are configured in parallel to each other.

17. The solid-state battery of claim 1, further comprising a dielectric structure located between the second bus bar and the substrate and laterally adjacent to each of the solid-state thin-film batteries of the array of solid-state thin-film batteries.