Thin film buried anode battery

• US 20070009802A1
• Filed: 07/29/2004
• Published: 01/11/2007
• Est. Priority Date: 11/13/2001
• Status: Active Grant

• Current Assignee: Alliance For Sustainable Energy LLC
• Original Assignee: Alliance For Sustainable Energy LLC
• Inventors: Lee, Se-Hee, Liu, Ping, Tracy, C.
• Granted Patent: US 7,632,602 B2
• Time in Patent Office: Days
• US Class Current: 429/245
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• 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 4/0421 involving vapour deposition
• CPC Class Codes: H01M 4/0426 Sputtering
• CPC Class Codes: H01M 4/0438 by electrochemical processing electroless electrochemical plating C23C18/54
• CPC Class Codes: H01M 4/0445 Forming after manufacture of the electrode, e.g. first charge, cycling
• CPC Class Codes: H01M 4/1391 of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1395 of electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/382 Lithium H01M4/405 takes precedence
• 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: 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 29/49115 including coating or impregnating

Abstract

A reverse configuration, lithium thin film battery (300) having a buried lithium anode layer (305) and process for making the same. The present invention is formed from a precursor composite structure (200) made by depositing electrolyte layer (204) onto substrate (201), followed by sequential depositions of cathode layer (203) and current collector (202) on the electrolyte layer. The precursor is subjected to an activation step, wherein a buried lithium anode layer (305) is formed via electroplating a lithium anode layer at the interface of substrate (201) and electrolyte film (204). The electroplating is accomplished by applying a current between anode current collector (201) and cathode current collector (202).

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16. A lithium secondary battery composite precursor comprising:

a) an anode current collector layer that has at least one conductive face and is characterized by its ability to function as a self-supporting substrate

b) an electrolyte layer, one face of which is in communication with a conductive face of said anode current collector layer, wherein said electrolyte layer is a conductor of lithium ions and exhibits chemical stability upon contact with lithium metal;

c) a cathode layer that is in communication with a face of said electrolyte layer that is not in communication with said anode current collector layer; and

d) a cathode current collector layer that is in communication with a face of the cathode layer that is not in communication with the electrolyte layer, the composite precursor being characterized by its ability to form a buried lithium anode layer at the interface between said anode current collector and said electrolyte when a current is maintained between the anode current collector and the cathode current collector, and its ability to be chemically stable when exposed to an ambient environment.

17. The composite structure of claim 16 having an anode current collector comprising a stainless steel, an electrolyte comprising sub-stoichiometric lithium phosphorous oxynitride, and a cathode layer comprising a material of the formula Li_xV₂O₅, where X is about 3 or greater.

18. A lithium thin film secondary battery comprising:

a) an anode current collector layer that has at least one conductive face and is characterized by its ability to function as a self-supporting substrate

b) a buried anode layer comprising lithium metal in communication with a conductive face of said anode current collector;

c) an electrolyte layer, one face of which is in communication with said anode layer;

d) a cathode layer that is in communication with a face of said electrolyte layer that is not in communication with said anode layer; and

e) a cathode current collector layer that is in communication with a face of the cathode layer that is not in communication with the electrolyte layer, the battery being characterized by an increase in the amount of metallic lithium contained in its buried anode layer upon charging and a reduction in the amount of lithium metal in its buried anode layer upon discharging, and its chemical stability when exposed to an ambient environment in any state of charge.

19. The battery of claim 18 having an anode current collector comprising a stainless steel, an electrolyte comprising sub-stoichiometric lithium phosphorous oxynitride, and a cathode layer comprising a material of the formula Li_xV₂O₅, where in the uncharged state, x is about 3 or greater.

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