THREE-DIMENSIONAL THIN FILM BATTERY

• US 20170237124A1
• Filed: 08/27/2015
• Published: 08/17/2017
• Est. Priority Date: 08/27/2014
• Status: Abandoned Application

• Current Assignee: Applied Materials Incorporated
• Original Assignee: Applied Materials Incorporated
• Inventors: KWAK, Byung Sung Leo, SONG, Daoying
• Application Number:
  US15/504,590
• Publication Number:
  US 20170237124A1
• Time in Patent Office: Days
• 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 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2300/0068 inorganic
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0407 by coating on an electrolyte layer
• CPC Class Codes: H01M 4/0426 Sputtering
• CPC Class Codes: H01M 4/0471 involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• 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 4/525 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 4/70 characterised by shape or form
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• 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 battery may comprise: a substrate comprising a substrate surface; a first current collector (FCC) layer formed on the substrate surface, the FCC layer having a first FCC surface and a second FCC surface and wherein the first FCC surface is in contact with the substrate and the second FCC surface is a first three-dimensional surface; a first electrode layer deposited on the first current collector, and an electrolyte layer deposited on the first electrode layer; wherein the interface between the first electrode layer and the electrolyte layer is a second three-dimensional surface roughly in conformity with the first three-dimensional surface. In embodiments, the substrate surface is a third three-dimensional surface and the first three-dimensional surface is roughly in conformity with the third three-dimensional surface. One of the first or the third three-dimensional surfaces may be formed by a laser ablation patterning process.

Claims

1. A thin film battery, comprising:

a substrate comprising a substrate surface;

a first current collector (FCC) layer formed on said substrate surface, said FCC layer having a first FCC surface and a second FCC surface and wherein said first FCC surface is in contact with said substrate and said second FCC surface is a first three-dimensional surface;

a first electrode layer deposited on said first current collector, and

an electrolyte layer deposited on said first electrode layer;

wherein the interface between said first electrode layer and said electrolyte layer is a second three-dimensional surface roughly in conformity with said first three-dimensional surface.

2. The thin film battery of claim 1, wherein said first three-dimensional surface comprises an array of patterned shapes.

3. The thin film battery of claim 1, wherein said substrate surface is a third three-dimensional surface and said first three-dimensional surface is roughly in conformity with said third three-dimensional surface.

4. The thin film battery of claim 1, further comprising:

a second electrode layer deposited on said electrolyte layer; and

a second current collector (SCC) layer deposited on said second electrode layer;

wherein said electrolyte layer is deposited on said first electrode layer and wherein the interface between said second electrode layer and said electrolyte layer is a fourth three-dimensional surface roughly in conformity with said first three-dimensional surface.

5. The thin film battery of claim 4, wherein the interface between said second electrode layer and said SCC layer is a fifth three-dimensional surface roughly in conformity with said fourth three-dimensional surface.

6. The thin film battery of claim 1, wherein said FCC layer is a cathode current collector layer and said first electrode layer is a cathode layer.

7. The thin film battery of claim 1, wherein said FCC layer is an anode current collector layer and said first electrode layer is an anode layer.

8. The thin film battery of claim 4, wherein said FCC layer is a cathode current collector layer and said first electrode layer is a cathode layer, and wherein said second electrode layer is an anode and said SCC layer is an anode current collector layer.

9. The thin film battery of claim 4, wherein said FCC layer is an anode current collector layer and said first electrode layer is an anode layer, and wherein said second electrode layer is a cathode and said SCC layer is a cathode current collector layer.

10. A method of manufacturing a thin film battery, comprising:

providing a substrate;

three-dimensionally restructuring the surface of said substrate to form a restructured substrate surface;

depositing a first current collector (FCC) layer on said restructured substrate surface;

depositing an electrode layer on said FCC layer; and

depositing an electrolyte layer on said electrode layer;

wherein the interface between said electrode layer and said electrolyte layer is a first three-dimensional surface roughly in conformity with said restructured substrate surface.

11. The method of claim 10, further comprising:

depositing a second electrode layer on said electrolyte layer;

wherein the interface between said electrolyte layer and said second electrode layer is a second three-dimensional surface roughly in conformity with said restructured substrate surface.

13. The method of claim 10, wherein said three-dimensionally restructuring comprises a laser ablation patterning process.

12. A method of manufacturing a thin film battery, comprising:

providing a substrate;

depositing a first current collector (FCC) layer on the surface of said substrate;

three-dimensionally restructuring the surface of said FCC layer to form a restructured FCC surface;

depositing a first electrode layer on said restructured FCC surface; and

depositing an electrolyte layer on said first electrode layer;

wherein the interface between said first electrode layer and said electrolyte layer is a first three-dimensional surface roughly in conformity with said restructured FCC surface.

14. The method of claim 12, wherein said three-dimensionally restructuring comprises a mechanical roughening process.

15. The method of claim 12, further comprising:

depositing a second electrode layer on said electrolyte layer;

wherein the interface between said electrolyte layer and said second electrode layer is a second three-dimensional surface roughly in conformity with said restructured first current collector surface.

16. The method of claim 12, wherein said three-dimensionally restructuring comprises a laser ablation patterning process.