Thin-film laminated body, thin-film cell, capacitor, and method and equipment for manufacturing thin-film laminated body

• US 20050141170A1
• Filed: 03/24/2003
• Published: 06/30/2005
• Est. Priority Date: 03/26/2002
• Status: Abandoned Application

• Current Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Inventors: Inaba, Junichi, Itoh, Syuuji, Higuchi, Hiroshi, Okazaki, Sadayuki, Honda, Kazuyoshi, Mino, Shinji, Takai, Yoriko, Sakai, Hitoshi
• Application Number:
  US10/508,060
• Publication Number:
  US 20050141170A1
• Time in Patent Office: Days
• US Class Current: 361/311
• CPC Class Codes: B32B 2457/10 Batteries
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: C23C 14/042 using masks
• CPC Class Codes: H01G 4/145 vapour deposited
• CPC Class Codes: H01G 4/306 made by thin film techniques
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0562 Solid materials
• CPC Class Codes: H01M 10/058 Construction or manufacture
• 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 4/139 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

A thin film layered product is composed of at least two deposition units, each of which includes at least a first thin film layer and a second thin film layer. At least one of the first thin film layer and the second thin film layer in each of the at least two deposition units is laminated so as to have an area decreased in a direction from a lower layer toward an upper layer. Thus, the reliability of connection between layers can be improved, and when a protective layer is formed on side faces, the formability and adhesion strength can be improved.

Claims

1. A thin film layered product comprising at least two deposition units, each of which includes at least a first thin film layer and a second thin film layer,

wherein at least one of the first thin film layer and the second thin film layer in each of the at least two deposition units has an area decreased in a direction from a lower layer toward an upper layer.

2. The thin film layered product according to claim 1,

wherein the thin film layered product has substantially the shape of a trapezoid in cross section along a layering direction.

3. The thin film layered product according to claim 1,

wherein the first thin film layers and/or the second thin film layers in the at least two deposition units are connected electrically to each other.

4. The thin film layered product according to claim 1,

wherein each of extraction electrodes connected electrically to the first thin film layers and the second thin film layers in the at least two deposition units, respectively, is formed in at least a portion on a face other than both end faces in a layering direction.

5. The thin film layered product according to claim 1,

wherein a protective layer is provided in at least a portion on a face other than both end faces in a layering direction.

6. The thin film layered product according to claim 1,

wherein each of the first thin film layer and the second thin film layer is substantially rectangular in plan shape.

7. A thin film battery comprising at least two deposition units, each of which includes at least a current collector layer, a positive active material layer, a solid electrolyte layer, and a negative active material layer,

wherein at least one of the current collector layer, the positive active material layer, the solid electrolyte layer, and the negative active material layer in each of the at least two deposition units has an area decreased in a direction from a lower layer toward an upper layer.

8. A capacitor comprising at least two deposition units, each of which includes at least a dielectric layer and an electrode layer,

wherein at least one of the dielectric layer and the electrode layer in each of the at least two deposition units has an area decreased in a direction from a lower layer toward an upper layer.

9. A method for manufacturing a thin film layered product comprising by taking as one unit:

a step of laminating a first thin film layer patterned into a predetermined shape; and

a step of laminating a second thin film layer patterned into a predetermined shape, the unit of steps being performed repeatedly on a carrier, whereby the thin film layered product is manufactured that is composed of at least two deposition units, each of which includes at least the first thin film layer and the second thin film layer,

wherein at least one of the first thin film layer and the second thin film layer in each of the at least two deposition units is laminated so as to have an area decreased with an increasing number of times the lamination is carried out.

10. The method according to claim 9,

wherein before each of materials of the first thin film layer and the second thin film layer is deposited, oil is applied in a predetermined region, whereby each of the first thin film layer and the second thin film layer is pattered into a predetermined shape.

11. The method according to claim 10,

wherein at least one of an area in which the oil is applied before the material of the first thin film layer is deposited and an area in which the oil is applied before the material of the second thin film layer is deposited is increased with increasing number of times the lamination is carried out.

12. The method according to claim 10,

wherein the oil is applied using at least one pair of nozzles, each of which has micro-holes arranged so as to be opposed to the carrier, and

while the carrier is allowed to travel in one direction, each of the nozzles is allowed to move back and forth in directions substantially orthogonal to the one direction in which the carrier is allowed to travel so that tracks formed on the carrier by the micro-holes of one of the nozzles and tracks formed on the carrier by the micro-holes of the other of the nozzles intersect each other.

13. The method according to claim 12,

wherein at least one of the first thin film layer and the second thin film layer is patterned by applying the oil in such a manner that a distance between a surface on which the oil is allowed to adhere and the micro-holes is increased with increasing number of times the lamination is carried out.

14. An apparatus for manufacturing a thin film layered product, comprising:

a rotating carrier;

a first thin film layer forming device that is opposed to the carrier and allows a material of a first thin film layer to be deposited on a surface of the carrier;

a second thin film layer forming device that is opposed to the carrier and allows a material of a second thin film layer to be deposited on the surface of the carrier; and

a patterning device that is opposed to the carrier and patterns each of the first thin film layer and the second thin film layer into a predetermined shape,

wherein the patterning device performs patterning with respect to at least one of the first thin film layer and the second thin film layer so that the at least one of the first thin film layer and the second thin film layer has an area decreased with an increasing number of rotations of the carrier.

15. The apparatus according to claim 14,

wherein the patterning device is an oil application device that is arranged on an upstream side of the first thin film layer forming device and the second thin film layer forming device in a rotation direction of the carrier.

16. The apparatus according to claim 15,

wherein the oil application device includes at least one pair of nozzles in each of which micro-holes are arranged, and each of the nozzles in a pair is allowed to move so that tracks formed on the carrier by the micro-holes of one of the nozzles in the pair and tracks formed on the carrier by the micro-holes of the other of the nozzles in the pair intersect each other.

17. The apparatus according to claim 16,

wherein when at least one of the first thin film layer and the second thin film layer is patterned, oil is applied in such a manner that a distance between a surface on which the oil is allowed to adhere and the micro-holes is increased in synchronization with rotation of the carrier.