Method for manufacturing a thin-film lithium battery by direct deposition of battery components on opposite sides of a current collector

• US 6,398,824 B1
• Filed: 10/10/2000
• Issued: 06/04/2002
• Est. Priority Date: 04/02/1999
• Status: Expired due to Term

• Current Assignee: Johnson Ip Holding Llc
• Original Assignee: Excellatron Solid State, LLC
• Inventors: Johnson, Lonnie G.
• Primary Examiner(s): Brouillette, Gabrielle
• Assistant Examiner(s): TSANG FOSTER, SUSY N
• Application Number:
  US09/684,899
• Time in Patent Office: 602 Days
• Field of Search: 429/127, 429/162, 429/231.95, 296/231, 296/235
• US Class Current: 29/623.1
• 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 10/0525 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 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0426 Sputtering
• CPC Class Codes: H01M 4/139 Processes of manufacture
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• 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
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A method of manufacturing a thin film battery cell (10) is disclosed wherein a cathode current collector (11) is passed through a cathode chamber wherein two oppositely disposed cathode layers (12) are deposited upon opposite faces of the cathode current collector (11). Two oppositely disposed electrolyte layers (13) are then deposited upon opposite faces of the combination of the cathode current collector (11) and cathode layers (12). Two oppositely disposed anode layers (14) are then deposited upon opposite faces of the combination of the cathode current collector (11), cathode layers (12) and electrolyte layers (13). An anode current collector (16) may then be coupled to the two anode layers (14).

Claims

1. A method of manufacturing a thin film battery comprising the steps of:

(a) providing a substantially planar cathode current collector having two oppositely disposed generally planar surfaces;

(b) depositing a first cathode layer upon one cathode current collector surface;

(c) depositing a second cathode layer upon the other cathode current collector surface;

(d) depositing a first electrolyte layer upon the first cathode layer;

(e) depositing a second electrolyte layer upon the second cathode layer;

(f) depositing a first anode layer upon the first electrolyte layer, and

(g) depositing a second anode layer upon the second electrolyte layer.

2. The method of claim 1 wherein steps (b) and (c) are performed in sequence.

3. The method of claim 1 wherein steps (b) and (c) are performed simultaneously.

4. The method of claim 1 wherein the first and second cathode layers are comprised of a lithium intercalation material.

5. The method of claim 1 further comprising step (h) of coupling the first and second anodes to an anode current collector.

6. The method of claim 1 further comprising the step of annealing the cathode current collector prior to step (b).

7. The method of claim 1 further comprising the step of annealing the first and second cathode layers prior to step (d).

8. The method of claim 6 further comprising the step of annealing the first and second cathode layers prior to step (d).

9. A method of producing a thin film battery comprising the steps of:

(a) providing a substantially planar cathode current collector;

(b) depositing two oppositely disposed cathode layers upon opposite sides of the cathode current collector;

(c) depositing two oppositely disposed electrolyte layers upon the combined cathode current collector and cathode layers, and

(d) depositing two oppositely disposed anode layers upon the combined electrolyte, cathode current collector, and cathode layers.

10. The method of claim 9 wherein the cathode layers are comprised of a lithium intercalation material.

11. The method of claim 9 further comprising step (e) coupling the anode layers to an anode current collector.

12. The method of claim 9 further comprising the step of annealing the cathode current collector prior to step (b).

13. The method of claim 9 further comprising the step of annealing the cathode layers prior to step (c).

14. The method of claim 12 further comprising the step of annealing the cathode layers prior to step (c).

15. A method of producing a thin film battery comprising the steps of:

(a) providing a cathode current collector;

(b) depositing a cathode upon opposite sides of the cathode current collector;

(c) depositing an electrolyte upon opposite sides of the cathode and cathode current collector combination, and

(d) depositing an anode upon opposite sides of the electrolyte, cathode and cathode current collector combination.

16. The method of claim 15 wherein the cathode is comprised of a lithium intercalation material.

17. The method of claim 15 further comprising step (e) of coupling the anode to an anode current collector.

18. The method of claim 15 further comprising the step of annealing the cathode current collector prior to step (b).

19. The method of claim 15 further comprising the step of annealing the cathode prior to step (c).

20. The method of claim 18 further comprising the step of annealing the cathode prior to step (c).

21. A method of producing a thin film battery comprising the steps of:

(a) providing a substantially planar first electrode current collector;

(b) depositing two oppositely disposed first electrode layers upon opposite sides of the first electrode current collector;

(c) depositing two oppositely disposed electrolyte layers upon the combined first electrode current collector and first electrode layers, and

(d) depositing two oppositely disposed second electrode layers upon the combined electrolyte, first electrode current collector, and first electrode layers.

22. The method of claim 21 wherein the first electrode layers are cathodes.

23. The method of claim 22 wherein the cathode layers are comprised of a lithium intercalation material.

24. The method of claim 21 further comprising the step of annealing the first electrode current collector prior to step (b).

25. The method of claim 23 further comprising the step of annealing the cathode prior to step (c).

26. The method of claim 21 wherein said first electrode layers are anodes.

27. The method of claim 26 wherein said second electrode layers are cathodes.