Thin-film electrochemical devices on fibrous or ribbon-like substrates and method for their manufacture and design

• US 20030064292A1
• Filed: 09/11/2002
• Published: 04/03/2003
• Est. Priority Date: 09/12/2001
• Status: Abandoned Application

• Current Assignee: ITN Energy Systems, Inc.
• Original Assignee: ITN Energy Systems, Inc.
• Inventors: Armstrong, Joseph H., Neudecker, Bernd J., Lanning, Bruce, Emerson, Brian K., Benson, Martin H.
• Application Number:
  US10/238,606
• Publication Number:
  US 20030064292A1
• Time in Patent Office: Days
• US Class Current: 429/235
• CPC Class Codes: D02G 3/441 Yarns or threads with antistatic, conductive or radiation-shielding properties electroconductive, anti-static or radiation-shielding filaments D01F1/09, D01F1/106; anti-static fabrics D03D15/533; conducting, insulating or anti-static layers for floor coverings D06N7/0042
• CPC Class Codes: H01M 14/005 Photoelectrochemical storage cells light sensitive devices H01G9/20, semiconductors sensitive to light H01L31/00
• CPC Class Codes: H01M 50/124 having a layered structure
• 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: Y10T 29/49115 including coating or impregnating

Abstract

The fabrication of functional thin-film patterns, such as solid-state thin-film batteries on substrates having fibrous, or ribbon-like or strip-like geometry is disclosed. The present invention relates additionally to the design and manufacture of multiple-layer and multi-function thin films.

Claims

1. A method for depositing patterned thin films comprising the steps of:

providing a fibrous substrate;

depositing a plurality of functional layers on portions of said substrate; and

defining said portions in accordance with a function of said functional layer.

2. The method of claim 1 wherein one or more of said functional layers comprises a layer selected from a group consisting of:

an anode current collector layer;

an anode layer;

an electrolyte layer;

a cathode layer;

a cathode current collector layer;

an overlayer;

a photoactive layer;

an n-type window layer;

a p-type absorber layer;

a transparent conductive layer;

an electrically conductive layer;

a metallic layer;

a semiconductor layer;

an optically transmitive layer;

a thermally insulating layer;

a thermally conductive layer;

a weatherproofing layer;

cell contact layer;

a via layer;

a bus layer;

a printed circuit layer;

a sheath layer;

a lubricating layer;

a colored layer;

a grip layer;

a buffer layer; and

an auxiliary layer.

3. The method of claim 1, wherein said functional layers are arranged in an exposed anode battery configuration.

4. The method of claim 1, wherein said functional layers are arranged in a buried anode battery configuration.

5. The method of claim 1, wherein said functional layers are arranged in a lithium-based battery configuration.

6. The method of claim 1, wherein said functional layers are arranged in a lithium-ion based battery configuration.

7. The method of claim 1, wherein said functional layers are arranged in a lithium-free battery configuration.

8. The method of claim 1, wherein said functional layers are arranged in a sodium based battery configuration.

9. The method of claim 1, wherein said functional layers are arranged in a proton based battery configuration.

10. The method of claim 1, wherein said step of depositing a plurality of functional layers on portions of said substrate comprises a shadow masking technique.

11. The method of claim 1, wherein said step of defining said portions in accordance with a function of said functional layer comprises a shadow masking technique.

12. The method of claim 1, further comprising applying one or more functional layers to said substrate by means of a shadow masking technique.

13. An apparatus for use as a functional thin-film pattern on a substrate comprising:

a fibrous substrate; and

a plurality of functional layers on portions of said fibrous substrate, wherein said portions are selected according to a desired function of said pattern.

14. The apparatus of claim 13, wherein said portions define an electrochemical cell.

15. The apparatus of claim 14, wherein said electrochemical cell comprises a device selected from a group consisting of:

a lithium anode battery;

a buried lithium anode battery;

a lithium-ion anode battery;

a buried lithium-ion anode battery;

a lithium-free anode battery;

a buried lithium-free anode battery;

a nickel metal hydride configuration;

a NiCd configuration; and

a copper-indium-gallium-selenide photovoltaic device.

16. The apparatus of claim 13, wherein said portions define an multilayer interconnect.

17. The apparatus of claim 13, wherein said substrate comprises a fiber.

18. The apparatus of claim 17, wherein said fiber comprises a circular fiber.

19. The apparatus of claim 17, wherein said fiber comprises an elliptical fiber.

20. The apparatus of claim 13, wherein a first plurality of said portions do not overlap with a second plurality of said portions.

21. The apparatus of claim 20, wherein said first and second pluralities of said portions define a first device and a second device, wherein at least one of said first device and said second device comprises a device type selected from a group consisting of a lithium anode battery, a buried lithium anode battery, a lithium-ion anode battery, a buried lithium-ion anode battery, a lithium-free anode battery, a buried lithium-free anode battery, a nickel metal hydride configuration, a NiCd configuration, a copper-indium-gallium-selenide photovoltaic device, and a multilayer interconnect.

22. The apparatus of claim 21, wherein said first device comprises the same device type as said second device.

23. The apparatus of claim 21, wherein said first device comprises a complimentary device type to said second device.

24. The apparatus of claim 13, wherein said portions are defined by shadow masking.

25. The apparatus of claim 13, wherein said functional layers are deposited on said fibrous substrate by shadow masking.

26. An apparatus for use as an electrochemical device on a substrate comprising:

a substrate; and

a plurality of electrochemical layers formed on selected portions of said substrate, wherein said electrochemical layers comprise an electrolyte layer and a cathode layer, and wherein said electrolyte layer is provided at least partially between said cathode layer and substrate.

27. The apparatus of claim 26, wherein said electrochemical layers comprise an anode current collector layer on said substrate, an electrolyte layer on said anode current collector layer, a cathode layer on said electrolyte layer, and a cathode current collector layer on said cathode layer.

28. The apparatus of claim 27, wherein said electrochemical layers further comprise an anode layer between said anode current collector layer and said electrolyte layer.

29. The apparatus of claim 28, wherein said anode layer comprises a layer selected from a group consisting of a lithium metal anode layer and a lithium-ion anode layer.

30. A method for depositing electrochemical layers comprising the steps of:

providing a substrate; and

forming a plurality of electrochemical layers on selected portions of said substrate, wherein said forming provides at least a cathode layer and an electrolyte layer, and wherein said electrolyte layer is provided between said cathode layer and said substrate.

31. The method of claim 30, wherein said electrochemical layers comprise an anode current collector layer on said substrate, an electrolyte layer on said anode current collector layer, a cathode layer on said electrolyte layer, and a cathode current collector layer on said cathode layer.

32. The method of claim 31, further comprising providing an anode layer between said anode current collector layer and said electrolyte layer.

33. The method of claim 32, wherein said anode layer comprises a layer selected from a group consisting of a lithium metal anode layer and a lithium-ion anode layer.