Electrochemical apparatus with barrier layer protected substrate
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Abstract
The present invention relates generally to fabricating well performing thin-film batteries onto metallic substrates, polymeric substrates, and doped and undoped silicon substrates. More specifically, the invention may include fabricating an appropriate diffusion barrier layer between the substrate and the battery part of the present invention that separates said two parts chemically during the entire battery fabrication process and the operation and storage conditions of the electrochemical apparatus during its entire lifetime. In one embodiment of the present invention, thin-film batteries fabricated onto a thin, flexible, stainless steel foil substrate using an appropriate diffusion layer show uncompromised electrochemical performance compared to thin-film batteries fabricated onto ceramic substrates when using a 700° C. post-deposition anneal process for the LiCoO2 positive cathode.
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Citations
282 Claims
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1-264. -264. (canceled)
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265. An electrochemical apparatus comprising a substrate further comprising a first side, a first electrochemically active cell on said first side, and a first barrier layer on said first side which chemically separates said first electrochemically active cell from said substrate, and wherein:
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(a) said first barrier layer is not a pure oxide;
(b) said substrate is not selected from the group Zr and Ti;
(c) said substrate is not Al that is coated with metals or semi-metals selected from the group V, Mn, Mg, Fe, Ge, Cr, Ni, Zn, and Co;
(d) said first electrochemically active cell is not equipped with a LixV2Oy cathode wherein 0<
x≦
100 and 0<
y≦
5;
(e) said first electrochemically active cell is not a solar battery;
(f) said barrier layer comprises an electrically insulating material; and
(g) said substrate is selected from the group consisting of metallic substrate, polymeric substrate, and doped or undoped silicon substrate. - View Dependent Claims (266, 267, 268, 269, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279)
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280. An electrochemical apparatus comprising a substrate with a first side, a first electrochemically active cell on said first side, and a first barrier layer on said first side which is adapted to chemically separate said first electrochemically active cell from said substrate;
- and with a second side, a second electrochemically active cell on said second side, and a second barrier layer on said second side which chemically separates said second electrochemically active cell from said substrate and wherein;
(a) said barrier layers on both substrate sides are not pure oxides;
(b) said substrate is not selected from the group Zr and Ti;
(c) said substrate does not comprise Al that is coated with metals or semi-metals selected from the group V, Mn, Mg, Fe, Ge, Cr, Ni, Zn, and Co;
(d) said electrochemically active cells on both substrate sides are not equipped with a LixV2Oy cathode wherein 0<
x≦
100 and 0<
y≦
5;
(e) said electrochemically active cells on both substrate sides are not solar batteries; and
(f) said substrate is selected from the group consisting of metallic substrate, polymeric substrate, and doped or undoped silicon substrate. and wherein said barrier layers on both sides of said substrate separate chemically said electrochemically active cells from said substrate by virtue of;
(g) the chemical inertness of said first barrier layer on said first side of said substrate relative to said first electrochemically active cell on said first side of said substrate and relative to said substrate;
(h) the chemical inertness of said second barrier layer on said second side of said substrate relative to said second electrochemically active cell on said second side of said substrate and relative to said substrate;
(i) the diffusion blocking properties of said first barrier layer on said first side of said substrate relative to the electrons or the ions of any of the chemical elements of said first electrochemically active cell on said first side of said substrate; and
(j) the diffusion blocking properties of said second barrier layer on said second side of said substrate relative to the electrons or the ions of any of the chemical elements of said second electrochemically active cell on said second side of said substrate during the entire fabrication of said first electrochemically active cell on said first side of said substrate and said second electrochemically active cell on said second side of said substrate and during all operation and storage conditions of said electrochemical apparatus.
- and with a second side, a second electrochemically active cell on said second side, and a second barrier layer on said second side which chemically separates said second electrochemically active cell from said substrate and wherein;
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281. The method of fabricating an electrochemical apparatus comprising the following step sequence:
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(a) providing a substrate with a first and a second side wherein said substrate is selected from the group consisting of metallic substrate, polymeric substrate, and doped or undoped silicon substrate;
(b) depositing a first barrier layer on said first side;
(c) depositing a second barrier layer on said second side;
(d) fabricating a first electrochemically active cell on said first side on top of said first barrier layer, which in turn chemically separates said first electrochemically active cell from said substrate;
(e) fabricating a second electrochemically active cell on said second side on top of said second barrier layer, which in turn chemically separates said second electrochemically active cell from said substrate;
(f) wherein said first barrier layer and said second barrier layer are not selected to be a pure oxide;
(g) wherein said substrate is not selected from the group Zr and Ti;
(h) wherein said substrate is not selected to be Al that is coated with metals or semi-metals selected from the group V, Mn, Mg, Fe, Ge, Cr, Ni, Zn, and Co;
(i) wherein said first electrochemically active cell and said second electrochemically active cell are not equipped with a LixV2Oy cathode wherein 0<
x≦
100 and 0<
y≦
5; and
(j) wherein said first electrochemically active cell and said second electrochemically active cell are not used as solar batteries. - View Dependent Claims (282)
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Specification