Method for manufacturing electrochemical device

• US 20040058237A1
• Filed: 09/18/2003
• Published: 03/25/2004
• Est. Priority Date: 09/03/2001
• Status: Active Grant

• Current Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Inventors: Ugaji, Masaya, Iwamoto, Kazuya, Higuchi, Hiroshi, Okazaki, Sadayuki, Ito, Shuji, Honda, Kazuyoshi, Inaba, Junichi, Mino, Shinji, Takai, Yoriko, Sakai, Hitoshi, Shibano, Yasuyuki, Matsuda, Hiromu
• Granted Patent: US 7,425,223 B2
• Time in Patent Office: Days
• US Class Current: 429/209
• CPC Class Codes: C23C 14/0021 Reactive sputtering or evaporation
• CPC Class Codes: C23C 14/22 characterised by the process of coating
• CPC Class Codes: C23C 14/24 Vacuum evaporation
• CPC Class Codes: C23C 14/30 by electron bombardment
• CPC Class Codes: C23C 14/32 by explosion; by evaporation and subsequent ionisation of the vapours , e.g. ion-platingC23C14/34 - C23C14/48 take precedence
• 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 4/0423 Physical vapour deposition
• CPC Class Codes: H01M 4/139 Processes of manufacture
• CPC Class Codes: H01M 4/485 of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy H01M4/505, H01M4/525 take precedence
• 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 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
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49112 including laminating of indefinite length material
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

To provide an electrochemical device with a layer structure causing no deterioration of characteristics of materials, in the method for preparing an electrochemical device comprising a first current collector, a first electrode active material layer, a solid electrolyte layer, a second electrode active material layer and a second current collector, all of which are accumulated, the first electrode active material layer, the second electrode active material layer or the solid electrolyte layer is formed by supplying atoms, ions or clusters constituting the first electrode active material layer, the second electrode active material layer or the solid electrolyte layer to the substrate, while irradiating electrons or electromagnetic waves with energy prescribed according to the composition of the first electrode active material layer, the second electrode active material layer or the solid electrolyte layer.

Claims

1. A method for preparing an electrochemical device comprising a first current collector, a first electrode active material layer, a solid electrolyte layer, a second electrode active material layer and a second current collector, all of which are laminated, characterized in that

said method comprises a film formation step of forming said first electrode active material layer, said second electrode active material layer or said solid electrolyte layer by supplying atoms, ions or clusters constituting said first electrode active material layer, said second electrode active material layer or said solid electrolyte layer to said substrate, while irradiating electrons or electromagnetic waves with energy prescribed according to the composition of said first electrode active material layer, said second electrode active material layer or said solid electrolyte layer.

2. The method for preparing an electrochemical devise in accordance with claim 1, characterized in that said electrons or electromagnetic waves are irradiated to the surface of said substrate.

3. The method for preparing an electrochemical devise in accordance with claim 1, characterized in that said electrons or electromagnetic waves are irradiated to said atoms, ions, or clusters.

4. The method for preparing an electrochemical devise in accordance with claim 1, characterized in that the temperature for crystallization of a layer to be formed in said film formation step is higher than the temperature for crystallization, or the melting point, of layers other than the layer to be formed.

5. The method for preparing an electrochemical devise in accordance with claim 1, characterized in that the temperature of layers other than the layer to be formed in said film formation step is maintained in a range prescribed according to the composition thereof.

6. The method for preparing an electrochemical devise in accordance with claim 1, characterized in that the strength of said energy and heat exhausted from said substrate are adjusted so that the temperature of said substrate does not exceed the temperature for crystallization, or the melting point, of layers other than the layer to be formed in said film formation step.

7. The method for preparing an electrochemical devise in accordance with claim 1, characterized in that when a compound constituting the layer to be formed in said film formation step is an oxide or a nitride, a gas atmosphere containing oxygen or oxygen ions, or an inert gas atmosphere containing nitrogen or nitrogen ions, is used as an atmosphere for vapor-deposition.

8. The electrochemical device in accordance with any of claims 1 to 7, characterized in that said first electrode active material layer and said second electrode active material layer are crystalline and said solid electrolyte layer is amorphous.