Rechargeable battery having permeable anode current collector

• US 6,713,987 B2
• Filed: 02/28/2002
• Issued: 03/30/2004
• Est. Priority Date: 02/28/2002
• Status: Expired due to Term

• Current Assignee: KLA Corporation
• Original Assignee: Front Edge Technology, Inc (KLA Corporation)
• Inventors: Nieh, Kai-Wei, Krasnov, Victor, Lin, Chun-Ting, Chang, Fan-Hsiu
• Primary Examiner(s): TIBBITS, PIA FLORENCE
• Application Number:
  US10/087,423
• Publication Number:
  US 20030160589A1
• Time in Patent Office: 761 Days
• Field of Search: 320/107, 429/118, 429/119, 429/162, 429/110, 429/116, 429/117, 296/231
• US Class Current: 320/107
• CPC Class Codes: H01M 10/0472 Vertically superposed cells with vertically disposed plates
• CPC Class Codes: H01M 10/05 Accumulators with non-aqueous electrolyte H01M10/39 takes precedence
• CPC Class Codes: H01M 10/0562 Solid materials
• CPC Class Codes: H01M 10/38 Construction or manufacture
• CPC Class Codes: H01M 4/0445 Forming after manufacture of the electrode, e.g. first charge, cycling
• CPC Class Codes: H01M 4/64 Carriers or collectors
• CPC Class Codes: H01M 6/185 with oxides, hydroxides or oxysalts as solid electrolytes
• CPC Class Codes: H01M 6/188 Processes of manufacture
• 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 rechargeable battery has a battery cell at least partially enclosed by a casing. The battery cell comprises (1) a substrate; (2) a cathode and cathode current collector on the substrate, the cathode being electrically coupled to the cathode current collector; (3) an electrolyte electrically coupled to the cathode or cathode current collector; and (4) a permeable anode current collector having a first surface electrically coupled to the electrolyte and an opposing second surface, the permeable anode current collector: (1) having a thickness that is less than about 1000 Å and that is sufficiently small to allow cathode material to permeate therethrough to form an anode on the opposing second surface of the permeable anode current collector when the battery cell is electrically charged, and (2) that is absent an overlayer on the opposing second surface of the anode current collector. Positive and negative terminals are electrically connected to the battery cell. The permeable anode current collector may be a grid with perforations.

Claims

1. A rechargeable battery comprising:

(a) a casing;

(b) a battery cell at least partially enclosed by the casing, the battery cell comprising;

(1) a substrate,

(2) a cathode and cathode current collector on the substrate, the cathode being electrically coupled to the cathode current collector,

(3) an electrolyte electrically coupled to the cathode or cathode current collector, and

(4) a permeable anode current collector having a first surface electrically coupled to the electrolyte and an opposing second surface, the permeable anode current collector;

(1) having a thickness that is less than about 1000 Å and

that is sufficiently small to allow cathode material to permeate therethrough to form an anode on the second surface of the permeable anode current collector when the battery cell is electrically charged, and (2) that is absent an overlayer on the opposing second surface of the anode current collector; and

(c) positive and negative terminals that electrically connect to the battery cell.

2. A rechargeable battery according to claim 1 comprising a gap between the permeable anode current collector and the casing.

3. A rechargeable battery according to claim 2 wherein the gap comprises a gas or vacuum.

4. A rechargeable battery according to claim 3 wherein the gas comprises argon or dry air.

5. A rechargeable battery according to claim 1 comprising a plurality of battery cells that are electrically connected in a series or parallel arrangement.

6. A rechargeable battery according to claim 1 wherein the cathode comprises lithium.

7. A rechargeable battery according to claim 1 wherein the permeable anode current collector comprises a thickness that is sufficiently thin to allow the battery cell to be charged and discharged from between about 4.2 Volts and about 3 Volts, respectively, at least about 100 times, without a loss of energy storage capacity of more than about 20% relative to the initial energy storage capacity of the battery cell.

8. A rechargeable battery according to claim 1 wherein the permeable anode current collector comprises a thickness of less than about 500 Å

.

9. A rechargeable battery according to claim 8 wherein the permeable anode current collector comprises a thickness of at least about 50 Å

.

10. A rechargeable battery according to claim 1 wherein the permeable anode current collector comprises a grid.

11. A rechargeable battery according to claim 1 wherein the permeable anode current collector comprises copper.

12. A rechargeable battery comprising:

(a) a casing;

(b) a battery cell at least partially enclosed by the casing, the battery cell comprising;

(1) a substrate,

(2) a cathode and cathode current collector on the substrate, the cathode being electrically coupled to the cathode current collector,

(3) an electrolyte electrically coupled to the cathode or the cathode current collector, and

(4) a permeable anode current collector having a first surface electrically coupled to the electrolyte and an opposing second surface, the permeable anode current collector comprising a grid having perforations that allow cathode material to pass through the perforations to form an anode on the second surface or in the perforations when the battery cell is electrically charged; and

(c) positive and negative terminals that electrically connect to the battery cell.

13. A rechargeable battery according to claim 12 absent an overlayer deposited on the grid of the permeable anode current collector.

14. A rechargeable battery according to claim 12 comprising a gap between the permeable anode current collector and the casing.

15. A rechargeable battery according to claim 14 wherein the gap comprises a gas or vacuum.

16. A rechargeable battery according to claim 12 comprising a plurality of battery cells that are electrically connected in a series or parallel arrangement.

17. A rechargeable battery according to claim 12 wherein the cathode comprises lithium.

18. A method of forming a rechargeable battery, the method comprising:

(a) forming a battery cell by the steps of;

(1) forming a substrate,

(2) forming a cathode and cathode current collector on the substrate, the cathode being electrically coupled to the cathode current collector,

(3) forming an electrolyte electrically coupled to the cathode or the cathode current collector, and

(4) forming a permeable anode current collector having a first surface electrically coupled to the electrolyte and an opposing second surface, the permeable anode current collector having (1) a thickness that is less than about 1000 Å and

that is sufficiently small to allow cathode material to permeate therethrough to form an anode on the second surface of the permeable anode current collector, and (2) absent an overlayer on the second opposing surface when the battery cell is electrically charged;

(b) connecting positive and negative terminals to the battery cell; and

(c) enclosing the battery cell at least partially within a casing.

19. A method according to claim 18 wherein (b) comprises placing the battery cell in the casing to form a gap between the permeable anode current collector and the casing.

20. A method according to claim 19 comprising evacuating the gap to form a vacuum environment in the gap.

21. A method according to claim 19 comprising filling the gap with a gas.

22. A method according to claim 18 absent a step of depositing an overlayer on the permeable anode current collector.

23. A method according to claim 18 wherein (b) comprises placing a plurality of battery cells in the casing and electrically connecting the battery cells in a series or parallel arrangement.

24. A method according to claim 18 comprising forming a cathode comprising lithium.

25. A method according to claim 19 comprising forming a permeable anode current collector comprising a grid.

26. A method of forming a rechargeable battery, the method comprising:

(a) forming a battery cell by the steps of;

(1) forming a substrate,

(2) forming a cathode and cathode current collector on the substrate, the cathode being electrically coupled to the cathode current collector,

(3) forming an electrolyte electrically coupled to the cathode or the cathode current collector, and

(4) forming a permeable anode current collector having a first surface electrically coupled to the electrolyte and a second opposing surface, the permeable anode current collector comprising a grid having perforations that allow cathode material to pass through the perforations to form an anode on the second surface of the anode current collector or in the perforations when the battery cell is electrically charged;

(b) connecting positive and negative terminals to the battery cell; and

(c) enclosing the battery cell at least partially within a casing.

27. A method according to claim 26 wherein (b) comprises placing the battery cell in the casing to form a gap between the permeable anode current collector and the casing.

28. A method according to claim 26 absent a step of depositing an overlayer on the permeable anode current collector.

29. A method according to claim 26 comprising forming perforations in the grid that have a dimension sized at least about 0.1 mm and less than about 3 mm.