Method for manufacture and structure of multiple electrochemistries and energy gathering components within a unified structure

• US 8,597,722 B2
• Filed: 05/07/2012
• Issued: 12/03/2013
• Est. Priority Date: 11/07/2008
• Status: Active Grant

• Current Assignee: Sakti3, Inc
• Original Assignee: Sakti3, Inc
• Inventors: Albano, Fabio, Wang, Chia Wei, Sastry, Ann Marie
• Primary Examiner(s): Talbot, Brian K
• Application Number:
  US13/465,243
• Publication Number:
  US 20120219830A1
• Time in Patent Office: 575 Days
• Field of Search: 427/115, 427/466, 204/192.15, 204/192.18, 296/231, 296/235, 429 40- 44
• US Class Current: 427/115
• CPC Class Codes: H01G 11/04 Hybrid capacitors
• CPC Class Codes: H01G 11/34 characterised by carbonisation or activation of carbon
• CPC Class Codes: H01L 31/022441 Electrode arrangements specially adapted for back-contact solar cells
• CPC Class Codes: H01L 31/1804 comprising only elements of Group IV of the Periodic Table
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0562 Solid materials
• CPC Class Codes: H01M 10/4264 with capacitors
• CPC Class Codes: H01M 10/465 with solar battery as charging system
• CPC Class Codes: H01M 12/08 composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
• CPC Class Codes: H01M 16/00 Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 16/003 of fuel cells with other electrochemical devices, e.g. capacitors, electrolysers
• CPC Class Codes: H01M 16/006 of fuel cells with rechargeable batteries
• CPC Class Codes: H01M 2008/1095 Fuel cells with polymeric electrolytes
• CPC Class Codes: H01M 2300/0068 inorganic
• CPC Class Codes: H01M 4/0402 Methods of deposition of the material
• CPC Class Codes: H01M 4/0419 involving spraying
• CPC Class Codes: H01M 4/0421 involving vapour deposition
• CPC Class Codes: H01M 4/0423 Physical vapour deposition
• CPC Class Codes: H01M 4/0426 Sputtering
• CPC Class Codes: H01M 4/0428 Chemical vapour deposition
• CPC Class Codes: H01M 4/045 : Electrochemical coating; Electrochemical impregnation
• CPC Class Codes: H01M 4/382 : Lithium H01M4/405 takes precedence
• CPC Class Codes: H01M 4/505 : of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
• CPC Class Codes: H01M 4/5825 : Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
• CPC Class Codes: H01M 6/40 : Printed batteries , e.g. thin film batteries
• CPC Class Codes: H02S 40/38 : Energy storage means, e.g. batteries, structurally associated with PV modules
• CPC Class Codes: Y02E 10/547 : Monocrystalline silicon PV cells
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02E 70/30 : Systems combining energy storage with energy generation of non-fossil origin
• 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
• CPC Class Codes: Y10T 29/49115 : including coating or impregnating

Abstract

A method for using an integrated battery and device structure includes using two or more stacked electrochemical cells integrated with each other formed overlying a surface of a substrate. The two or more stacked electrochemical cells include related two or more different electrochemistries with one or more devices formed using one or more sequential deposition processes. The one or more devices are integrated with the two or more stacked electrochemical cells to form the integrated battery and device structure as a unified structure overlying the surface of the substrate. The one or more stacked electrochemical cells and the one or more devices are integrated as the unified structure using the one or more sequential deposition processes. The integrated battery and device structure is configured such that the two or more stacked electrochemical cells and one or more devices are in electrical, chemical, and thermal conduction with each other.

Claims

1. A method for using an integrated battery and device structure, the method comprising:

using two or more stacked electrochemical cells integrated with each other formed overlying a surface of a substrate, the two or more stacked electrochemical cells comprising related two or more different electrochemistries with one or more devices formed using one or more sequential deposition processes, the one or more devices being integrated with the two or more stacked electrochemical cells to form the integrated battery and device structure as a unified structure overlying the surface of the substrate,

whereupon the one or more stacked electrochemical cells and the one or more devices are integrated as the unified structure using the one or more sequential deposition processes, and

wherein the integrated battery and device structure is configured such that the two or more stacked electrochemical cells and one or more devices are in electrical, chemical, and thermal conduction with each other.

2. The method of claim 1 wherein the one or more sequential deposition processes is one of at least physical vapor deposition (PVD).

3. The method of claim 1 further comprising a separation region configured for heat transfer provided between the two or more electrochemical cells.

4. The method of claim 3 wherein the separation region configured for thermal transfer is formed from at least diamond (C), poly-diamond (poly-C), alumina, boron nitride, aluminum nitride, or silicon carbide.

5. The method of claim 1 wherein the two or more electrochemistries selected from at least lithium (Li), lithium-ion, lithium-metal-polymer (LiM-polymer), lithium (Li)-air, lead (Pb)-acid, nickel metal hydrate (Ni/MH), nickel-zinc (Ni/Zn), zinc (Zn)-air, molten salts (Na/NiCl2), zebra (NaAlCl4), nickel-cadmium (Ni/Cd), silver-zinc (Ag/Zn).

6. The method of claim 1 wherein the device comprises at least one of a microelectromechanical system (MEMS) sensing element, a fuel-cell, a photovoltaic device, a capacitor, or an ultracapacitor.

7. The method of claim 1 wherein the device comprises a hybrid combination of units selected from the group consisting of electrochemical cells, fuel-cells, photovoltaic cells, capacitors, ultracapacitors, piezoelectric, thermo-electric, microelectromechanical turbines and energy scavengers.

8. The method of claim 1 further comprising a monitoring device consisting of a data BUS in logic contact and communication with the one or more devices and a central computing and processing unit (CPU), the CPU having control over one or more individual elements.

9. The method of claim 8 wherein the monitoring device is configured to detect temperature T.

10. The method of claim 9 wherein the monitoring device is configured to detect stress within one or more components.

11. The method of claim 9 wherein the monitoring device is configured to detect gas and gaseous reaction by products from operation at least either the one or more electrochemical cells or one or more devices.

12. The method of claim 9 wherein the monitoring device is configured to detect lithium composition and a transition through an anode and a cathode separation layer.

13. The method of claim 9 further comprising one or more monitoring devices to maintain a safe operation of the two or more electrochemical cells or the one or more devices.

14. The method of claim 1 further comprising a cooling system consisting of liquid coolant or liquefied gases activated if temperature rises above a set threshold, the cooling system being in thermal contact with heat sinks designed to remove thermal energy using one or more conducting paths.

15. The method of claim 1 wherein the two or more electrochemical cells are configured using hybrid principles applied to optimize device architecture, schedule, energy and power density along with rechargeability and lifetime.