Method and system for constructing a rechargeable battery and battery structures formed with the method
First Claim
1. A method for building up thin-film battery components in a layup arrangement wherein the layup includes a cathode film, an electrolyte film and a lithium anode film, the method comprising the steps of:
- moving the surface of a substrate through one station at which a cathode material is deposited in a thin film upon the surface as the-substrate is moved through the one station;
moving the substrate surface through another station at which an electrolyte material is deposited in a thin film over the cathode film as the substrate is moved through the another station; and
then moving the substrate surface through yet another station at which lithium is deposited in a thin film over the electrolyte film as the substrate is moved through the yet another station.
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Accused Products
Abstract
A method and system for manufacturing a thin-film battery and a battery structure formed with the method utilizes a plurality of deposition stations at which thin battery component films are built up in sequence upon a web-like substrate as the substrate is automatically moved through the stations. At an initial station, cathode and anode current collector film sections are deposited upon the substrate, and at another station, a thin cathode film is deposited upon the substrate so to overlie part of the cathode current collector section. At another station, a thin electrolyte film is deposited upon so as to overlie the cathode film and part of the anode current collector film, at yet another station, a thin lithium film is deposited upon so as to overlie the electrolyte film and an additional part of the anode current collector film. Such a method accommodates the winding of a layup of battery components into a spiral configuration to provide a thin-film, high capacity battery and also accommodates the build up of thin film battery components onto a substrate surface having any of a number of shapes.
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Citations
23 Claims
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1. A method for building up thin-film battery components in a layup arrangement wherein the layup includes a cathode film, an electrolyte film and a lithium anode film, the method comprising the steps of:
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moving the surface of a substrate through one station at which a cathode material is deposited in a thin film upon the surface as the-substrate is moved through the one station; moving the substrate surface through another station at which an electrolyte material is deposited in a thin film over the cathode film as the substrate is moved through the another station; and then moving the substrate surface through yet another station at which lithium is deposited in a thin film over the electrolyte film as the substrate is moved through the yet another station. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for constructing a thin film battery including the steps of:
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providing a substrate having a surface; providing, at a first station, means for depositing a thin cathode film onto the substrate surface as the surface is moved through the first station; providing, at a second station, means for depositing a thin electrolyte film over the cathode film as the surface is moved through the second station; providing, at a third station, means for depositing a thin lithium anode film over the electrolyte coating as the surface is moved through the third station; and automatically moving the substrate surface through the first, second and third stations so that the thin cathode, electrolyte and lithium anode films are built up in sequence upon the substrate surface. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 21)
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19. In a rechargeable, thin-film battery including a substrate surface, a thin cathode film overlying the substrate surface, a thin electrolyte film overlying the cathode surface and a thin lithium anode film overlying the electrolyte film, the improvement characterized in that:
the substrate surface is provided with a flexible web, the cathode film, electrolyte film and anode film are supported in a layup arrangement along the surface of the web, and the web and the layup of films supported thereby are wound in a wound arrangement. - View Dependent Claims (20)
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22. A system for building up a layup of thin film battery components comprising:
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means disposed at a first station for depositing a thin cathode film onto the surface of a substrate as the substrate is moved through the first station; means disposed at a second station for depositing a thin electrolyte film over the deposited cathode film as the substrate is moved through the second station; means disposed at a third station for depositing a thin lithium anode film over the deposited electrolyte film as the substrate is moved through the third station; and means for moving the substrate surface in sequence through the first, second and third stations so that thin cathode, electrolyte and lithium anode films are built up in sequence upon the substrate surface. - View Dependent Claims (23)
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Specification