Apparatus and method for fracture absorption layer

• US 20040023106A1
• Filed: 08/02/2002
• Published: 02/05/2004
• Est. Priority Date: 08/02/2002
• Status: Active Grant

• Current Assignee: ITN Energy Systems, Inc.
• Original Assignee: ITN Energy Systems, Inc.
• Inventors: Neudecker, Bernd J., Benson, Martin H.
• Granted Patent: US 6,770,176 B2
• Time in Patent Office: Days
• US Class Current: 429/122
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0562 Solid materials
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 2300/0068 inorganic
• CPC Class Codes: H01M 2300/0082 Organic polymers
• CPC Class Codes: H01M 2300/0094 in the form of layered products, e.g. coatings
• CPC Class Codes: H01M 6/187 Solid electrolyte characterised by the form
• CPC Class Codes: H01M 6/188 Processes of manufacture
• 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

An apparatus for use as a fracture absorption layer, an apparatus for use as a electrochemical device, and methods of manufacturing the same are taught. The apparatuses and methods of the present invention may be of particular use in the manufacture of thin-film, lightweight, flexible or conformable, electrochemical devices such as batteries, and arrays of such devices. The present invention may provide many advantages including stunting fractures in a first electrochemical layer from propagating in a second electrochemical layer.

Claims

1. An apparatus for use as a fracture absorption layer comprising

a first electrochemical layer having a first side,

a second electrochemical layer having a first side, and

a third electrochemical layer adapted to stunt fractures, wherein said third electrochemical layer is disposed between at least a portion of said first side of said first electrochemical layer, and at least a portion of said first side of said second electrochemical layer

2. The apparatus of claim 1, wherein said first electrochemical layer comprises an electrolyte layer.

3. The apparatus of claim 1, wherein said first electrochemical layer comprises a material selected from the group consisting of a glassy thin-film electrolyte, LiAlF₄, Lipon, and a crystalline thin-film electrolyte.

4. The apparatus of claim 1, wherein said first electrochemical layer comprises a thickness of between approximately 0.05 to approximately 5 microns.

5. The apparatus of claim 1, wherein said first electrochemical layer comprises a thickness of between approximately 0.01 to approximately 2 microns.

6. The apparatus of claim 1, wherein said first electrochemical layer comprises a thickness of between approximately 0.5 to approximately 2 microns.

7. The apparatus of claim 1, wherein said third electrochemical layer is connected to at least a portion of said first side of said first electrochemical device by a technique selected from a group consisting of sputter deposition, physical vapor deposition, electron beam evaporation, electron-beam directed vapor deposition, thermal evaporation, plasma assisted thermal evaporation, ion plasma plating, cathodic arc plasma deposition, ion beam deposition, plasma assisted ion beam deposition, pulsed laser deposition, chemical vapor deposition, thermal chemical vapor deposition, plasma enhanced chemical vapor deposition, photo-chemical chemical vapor deposition, molecular beam epitaxy, sol-gel deposition, and spray pyrolysis deposition.

8. The apparatus of claim 1, wherein said third electrochemical layer comprises a fracture absorption layer.

9. The apparatus of claim 1, wherein said third electrochemical layer comprises a material having the structural characteristic selected from a group consisting of glassy, amorphous, nano-crystalline, ceramic, metallic, and composite.

10. The apparatus of claim 1, wherein said third electrochemical layer comprises a thickness of between about 0.005 microns and about 5 microns.

11. The apparatus of claim 1, wherein said third electrochemical layer comprises a thickness of between about 0.01 microns and about 0.5 microns.

12. The apparatus of claim 1, wherein said third electrochemical layer comprises a thickness of between about 0.05 microns and about 0.1 microns.

13. The apparatus of claim 1, wherein said third electrochemical layer comprises a material selected from a group consisting of the following:

an ionic conductor;

an electric insulator;

a mixed conductor;

elemental lithium;

alloyed lithium;

elemental phosphorus;

alloyed phosphorous;

elemental tin;

alloyed tin;

a single phase compound of LiaPSnbOcNd wherein 0<

a<

100, 0<

b<

100, 0<

c<

a/2+5/2+2b−

3d/2, and 0<

d<

a/3+5/3+4b/3−

2c/3;

a multi-phase compound of Li_aPSn_bO_cN_d wherein 0<

a<

100, 0<

b<

100, 0<

c<

a/2+5/2+2b−

3d/2, and 0<

d<

a/3+5/3+4b/3−

2c/3;

a single phase compound of Li_aPM_bO_cN_d wherein 0<

a<

100, 0<

b<

100, 0<

c<

a/2+5/2+b(Valence of M)/2−

3d/2, 0<

d<

a/3+5/3+b(Valence of M)/3−

2c/3, and M is an element selected from group 2 through 15 of the periodic table excluding the elements Li, P, and N;

a multi-phase compound of Li_aPM_bO_cN_d wherein 0<

a<

100, 0<

b<

100, 0<

c<

a/2+5/2+b(Valence of M)/2−

3d/2, 0<

d<

a/3+5/3+b(Valence of M)/3−

2c/3, and M is an element selected from group 2 through 15 of the periodic table excluding the elements Li, P, and N;

elemental M wherein M is an element selected from group 2 through 15 of the periodic table excluding the elements Li, P, and N;

alloyed M wherein M is an element selected from group 2 through 15 of the periodic table excluding the elements Li, P, and N;

a single phase compound of Li_aPM_bO_cN_dX_e wherein 0<

a<

100, 0<

b<

100, 0<

c<

a/2+5/2+b(Valence of M)/2−

3d/2−

e(Valence of X)/2, 0<

d<

a/3+5/3+b(Valence of M)/3−

2c/3−

e/3(Valence of X), 0<

e<

a/(Valence of X)+5/(Valence of X)+b(Valence of M)/(Valence of X)−

2c/(Valence of X)−

3d/(Valence of X), M is an element selected from group 2 through 15 of the periodic table excluding the elements Li, P, and N, and X is an element selected from S, Se, Te, F, Cl, Br, and I;

a multi-phase compound of Li_aPM_bO_cN_dX_e wherein 0<

a<

100, 0<

b<

100, 0<

c<

a/2+5/2+b(Valence of M)/2−

3d/2−

e(Valence of X)/2, 0<

d<

a/3+5/3+b(Valence of M)/3−

2c/3−

e/3(Valence of X), 0<

e<

a/(Valence of X)+5/(Valence of X)+b(Valence of M)/(Valence of X)−

2c/(Valence of X)−

3d/(Valence of X), M is an element selected from group 2 through 15 of the periodic table excluding the elements Li, P, and N, and X is an element selected from S, Se, Te, F, Cl, Br, and I;

Li₃N;

Li₂O;

LiF;

LiCl;

LiBr;

LiI;

Li₂Be₂O₃;

Li₄BeO₃;

Be;

BeO;

LiBO₂;

B;

B₂O₃;

BN;

Li₅AlO₄;

LiAlO₂;

LiAl₅O₈;

Al;

Al₂O₃;

AlN;

Li₂CO₃;

Li₄SiO₄;

Li₈SiO₆;

Si;

SiO₂;

Si₃N₄;

Li₄GeO₄;

Ge;

GeO₂;

Ge₃N₄;

Li₃PO₄;

P;

P₂O₅;

P₂O₅;

P₅N₃;

PN;

PON;

P₄ON₆;

Li₃AsO₄;

As;

As₂O₃;

As₂O₅;

Li₂SO₄;

S;

LiClO₄;

LiScO₂;

Sc;

Sc₂O₃;

LiYO₂;

Y;

Y₂O₃;

YN;

Li₈ZrO₆;

Zr;

ZrO₂;

ZrN;

LiCeO₂;

Ce;

CeO₂;

LiAlSiO₄;

LigSiAlO₈;

Li_3.6Si_0.6P_0.4O₄;

Li₃Sc₂(PO₄)₃;

LiTi₂(PO₄)₃;

Li_0.2BPO₄₁;

Li₃BN₂;

Li₃AlN₂;

LiSi₂N₃;

Li₂SiN₂;

Li₅SiN₃;

Li₁₈Si₃N₁₀;

Li₂₁Si₃N₁₁;

Li₈SiN₄;

LiPN₂;

Li₇PN₄;

LiAlF₄;

LiAlCl₄;

LiPF₆;

LiBF₄;

Li₃SiS₃₅;

Li_xV₂O_y (0<

x≦

2;

0<

y≦

5);

Li_xMn₂O₄ (0<

x≦

2);

LiMn_2-yO₄ (0<

x≦

3;

0.2<

y≦

0.5);

Li_xMnO₂ (0<

x≦

2.0);

Li_xCoO₂ (0<

x≦

1);

Li_xNiO₂ (0<

x≦

2);

Li_xSn₃N_y (0<

x≦

100;

0<

y≦

4.0);

Li_xInN_y (0<

x<

100;

0<

y≦

1.0);

Li_xZn₃N_y (0<

x<

100;

0<

y≦

2.0);

Li_xZnO_y (0<

x<

100;

0<

y≦

1.0);

Li_xCuN_y (0<

x<

100;

0<

y≦

0.33);

Li_xSiSn_0.9ON_1.9 (“

Siton”

;

0<

x<

100);

Li_xSnO_y (0<

x<

100;

0<

y≦

2.0);

Li_xAl (0<

x<

100);

Li_xIn (0<

x<

100);

Li_xC₆ (0<

x<

100);

Li_xSi (0<

x<

100);

Li_xSn (0<

x<

100);

Li_xP (0<

x<

100); and

Li_xZn (0<

x<

100).

14. The apparatus of claim 1, wherein said third electrochemical layer further comprises a polymer matrix.

15. The apparatus of claim 14, wherein said polymer matrix comprises a material selected from a group consisting of polyethelyene oxide, polyimide, polytetrafluoroethylene, polyester, and polyvinylpyrrolidone.

16. The apparatus of claim 1, further comprising

a fourth electrochemical layer, adapted to stunt fractures, having a first side and a second side,

a fifth electrochemical layer having a first side,

wherein said second electrochemical layer further comprises a second side,

wherein at least a portion of said first side of said fourth electrochemical device is connected to at least a portion of said second side of said second electrochemical layer, and

wherein at least a portion of said first side of said fifth electrochemical layer is connected to at least a portion of said second side of said fourth electrochemical layer.

17. An apparatus for use as an electrochemical device comprising

a first electrochemical layer having a first side,

a second electrochemical layer having a first side,

a third electrochemical layer adapted to stunt fractures, wherein said third electrochemical layer is disposed between at least a portion of said first side of said first electrochemical layer, and at least a portion of said first side of said second electrochemical layer, and

a substrate layer, wherein at least a portion of said first electrochemical layer is supported by said substrate layer.

18. The apparatus of claim 17, wherein said substrate layer comprises a geometry selected from a group consisting of planar, fibrous, ribbon-like, and cylindrical.

19. The apparatus of claim 17, wherein said substrate layer comprises a thickness of between approximately 1 micron and approximately 6.35 millimeters.

20. The apparatus of claim 17, wherein said substrate layer comprises a thickness of between approximately 25 microns and approximately 127 microns.

21. The apparatus of claim 17, wherein said substrate layer comprises a material selected from a group consisting of ceramic, metal, metal-alloy, glass, silicon, semiconductor, shape memory alloy, carbon, or polymer.

22. The apparatus of claim 17, wherein said substrate layer comprises a cylindrical geometry and a diameter of between approximately 1 micron and approximately 6.35 millimeters.

23. The apparatus of claim 17, wherein said substrate layer comprises a cylindrical geometry and a diameter of between approximately 10 microns and approximately 381 microns.

24. The apparatus of claim 17, wherein said substrate layer comprises a material adapted to be flexible.

25. The apparatus of claim 17, wherein said substrate layer comprises a material adapted to be conformable.

26. The apparatus of claim 17, further comprising an anode layer.

27. The apparatus of claim 26, wherein said anode layer comprises an anode type selected from the group consisting of lithium-metal, lithium-free, and lithium-ion.

28. The apparatus of claim 17, further comprising one or more electrode layers.

29. The apparatus of claim 28, wherein one or more of said electrode layers comprises a thickness of between approximately 0.05 microns and approximately 10 centimeters.

30. A method for manufacturing an electrochemical device comprising the steps of

providing a first electrochemical layer having a first side,

forming a second electrochemical layer adapted to stunt fractures on at least a portion of said first side of said first electrochemical device, and

forming a third electrochemical layer on at least a portion of said second electrochemical layer.

31. The method of claim 30, wherein said step of forming a second electrochemical layer comprises the steps of

providing a gaseous environment,

providing a sputter target, and

sputter-depositing said second electrochemical layer with said sputter target.

32. The method of claim 31, wherein said gaseous environment comprises one or more gases selected from the group consisting of Ar, N₂, and O₂.

33. The method of claim 31, wherein said gaseous environment consists of one or more gases selected from the group consisting of Ar, N₂, and O₂.

34. The method of claim 31, wherein said sputter target comprises a single phase target.

35. The method of claim 31, wherein said sputter target comprises a multi-phase target.

36. The method of claim 31, wherein said sputter target comprises a target comprising a material selected from a group consisting of Li₃PO₄, Li₄P₂O₇, LiPO₃, Li₃PO₃, Li₂O, Li₂O₂, Li₃N, P, P₂O₅, P₅N₃, PN, PON, P₄ON₆, Sn, Sn₃N₄, SnO₂, Sn(NO₃)₄, Li_xSn (0<

x≦

4.4), Li_xP (0<

x≦

3), Li₅SnP₃, Li₈SnP₄, Li₇PN₄, Li₁₀PN₁₀, LiPN₂, LiN₂P, Li_2.88PO_3.73N_0.14, Li₂SnO₃, Li₈SnO₆, Sn₄P₃, SnP, SnP₃, Sn₂P₂O₇, Sn₃(PO₄)₂, and Li.

37. The method of claim 31, wherein said sputter target comprises a target comprising a material selected from a group consisting of M, MN_x (0<

x<

1/3 valence of M), MO_x (0<

x<

1/2 valence of M), M(NO₃)_x (x=valence of M), Li_xM (alloy or solid solution of Li and M), and Li_xP (0<

x≦

3).

38. The method of claim 31, wherein said sputter target comprises a target comprising a material selected from a group consisting of S, sulfur nitride ((SN)_x), Se, SeO_x (x=2, 2.5, and 3), Te, TeO_x (x=2, 2.5, and 3), LiF, LiCl, LiBr, LiI, MS_x (0<

x<

1/2 times valence of M), MSe_x (0<

x<

1/2 times valence of M), MeF_x (x=valence of M), MeCl_x (x=valence of M), MeBr_x (x=valence of M), MeI_x (x=valence of M) and MeF_x (x=valence of M), M(SO₄)_x (x=1/2 valence of M), M(ClO₄)_x (x=valence of M), M(BrO₄)_x (x=valence of M), and M(IO₄)_x (x=valence of M).

39. The method of claim 31, wherein said sputter target comprises a target comprising a material selected from a group consisting of Li₂Be₂O₃, Li₄BeO₃, Be, BeO, LiBO₂, B, B₂O₃, BN, Li₅AlO₄, LiAlO₂, LiAl₅O₈, Al, Al₂O₃, AlN, Li₂CO₃, Li₄SiO₄, Li₈SiO₆, Si, Sio₂, Si₃N₄, Li₄GeO₄, Ge, GeO₂, Ge₃N₄, Li₃AsO₄, As, As₂O₃, AS₂O₅, Li₂SO₄, LiClO₄, LiScO₂, Sc, Sc₂O₃, LiYO₂, Y, Y₂O₃, YN, Li₈ZrO₆, Zr, ZrO₂, ZrN, LiCeO₂, Ce, CeO₂, LiAlSiO₄, Li₉SiAlO₈, Li_3.6Si_0.6P_0.4O₄, Li₃Sc₂(PO₄)₃, LiTi₂(PO₄)₃, Li_0.2BPO_4.1, Li₃BN₂, Li₃AlN₂, LiSi₂N₃, Li₂SiN₂, Li₅SiN₃, Li₁₈Si₃N₁₀, Li₂₁Si₃N₁₁, Li₈SiN₄, LiAlF₄, LiAlCl₄, LiPF₆, LiBF₄, and Li₃SiS_3.5.

40. The method of claim 30, wherein said step of forming a second electrochemical device further comprises forming a composite comprising a polymer matrix.

41. The method of claim 40, wherein said polymer matrix comprises a material selected from a group consisting of polyethelyene oxide, polyimide, polytetrafluoroethylene, polyester, and polyvinylpyrrolidone.

42. The method of claim 30, wherein said step of providing a first electrochemical layer comprises providing said first electrochemical layer supported by a substrate layer.

43. A method of stunting fractures in an electrolyte layer comprising the steps of

providing a first electrolyte layer having a first side,

providing an electrochemical layer adapted to stunt fractures, and

providing a second electrolyte layer having a first side, wherein said electrochemical layer is interposed between at least a portion of said first side of said first electrolyte layer, and at least a portion of said first side of said second electrolyte layer.

44. The method of claim 43, wherein said electrochemical layer comprises a material selected from a group consisting of the following:

an ionic conductor and an electronic insulator; and

an ionic conductor and an electronic conductor.