Amorphous cathode material for battery device

• US 9,627,709 B2
• Filed: 10/15/2014
• Issued: 04/18/2017
• Est. Priority Date: 10/15/2014
• Status: Active Grant

• Current Assignee: Sakti3, Inc
• Original Assignee: Sakti3, Inc
• Inventors: Zhang, Xiang Chun, Chung, Myoundo, Sastry, Ann Marie, Wang, Chia-Wei, Chen, Yen-Hung, Kim, Hyoncheol
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): Lewis, Ben
• Application Number:
  US14/514,779
• Publication Number:
  US 20160240884A1
• Time in Patent Office: 916 Days
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• 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 10/0585 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 2220/10 Batteries in stationary systems, e.g. emergency power source in plant
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 4/0402 Methods of deposition of the material
• CPC Class Codes: H01M 4/483 for non-aqueous cells H01M4/485 takes precedence
• 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: 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 method of fabricating a multilayered thin film solid state battery device. The method steps include, but are not limited to, the forming of the following layers: substrate member, a barrier material, a first electrode material, a thickness of cathode material, an electrolyte, an anode material, and a second electrode material. The formation of the barrier material can include forming a polymer material being configured to substantially block a migration of an active metal species to the substrate member, and being characterized by a barrier degrading temperature. The formation of cathode material can include forming a cathode material having an amorphous characteristic, while maintaining a temperature of about −40 Degrees Celsius to no greater than 500 Degrees Celsius such that a spatial volume is characterized by an external border region of the cathode material. The method can then involve transferring the resulting thin film solid state battery device.

Claims

1. A method of fabricating a multilayered thin film solid state battery device, the method comprising:

providing a substrate member, the substrate member comprising a surface region, the substrate member having a melting point temperature;

forming a barrier material comprising a polymer material overlying the surface region, the barrier material being configured to substantially block a migration of an active metal species to the substrate member, and being characterized by a barrier degrading temperature;

forming a first electrode material overlying the surface region;

forming a thickness of cathode material having an amorphous characteristic, while maintaining a temperature of about −

40 Degrees Celsius to no greater than 500 Degrees Celsius such that a spatial volume is characterized by an external border region of the cathode material, an effective diffusivity is characterizing the thickness of the cathode material and having a value ranging from 0.005 μ

m to 1000 μ

m, and a void region characterizing the thickness of cathode material, the void region being 0.001% to 20% of the spatial volume;

forming an electrolyte configured overlying the thickness of cathode material;

forming an anode material overlying the electrolyte;

forming a second electrode material overlying the anode material; and

transferring a thin film solid state battery device characterized by an energy density ranging from 50 Watt-hour/liter to 3000 Watt-hour/liter.

2. The method of claim 1, wherein the thickness of cathode material comprises a first thickness of amorphous material and a second thickness of material, the first thickness being greater than the second thickness, and the first thickness of amorphous material being different in structure than the second thickness of material.

3. The method of claim 1, wherein the thickness of cathode material comprises a first thickness of amorphous material and a second thickness of material, the first thickness being greater than the second thickness, and the first thickness of amorphous material being different in structure than the second thickness of material;

whereupon the effective diffusivity comprises a first diffusivity of the first thickness and a second diffusivity of the second thickness.

4. The method of claim 1, wherein the thickness of cathode material comprises a plurality of pillar-like structures, each of which extends along a direction of the thickness, and substantially normal to a plane of the thickness of material and the surface region.

5. The method of claim 1, wherein the barrier material comprises a polymer material, the polymer material being a thickness ranging from 0.001 μ

m to 1 μ

m to compensate a strain between the first electrode member and the surface region;

wherein the temperature is less than 900 Degrees Celsius.

6. The method of claim 1, wherein the cathode material comprises a lithium species, the lithium species being selected from at least one of LiSON, Li_xLa₁₋

xZrO₃, Li_xLa<sub>1−

x</sub>TiO₃, LiAlGePO₄, LiAlTiPO₄, LiSiCON, Li_1.3Al_0.3Ti_1.7(PO₄)₃, 0.5LiTaO_3+0.5SrTiO₃, Li_0.34La_0.51TiO_2.94, LiAlCl₄, Li₇SiPO₈, Li₉AlSiO₈, Li₃PO₄, Li₃SP₄, LiPON, Li₇La₃Zr₂O₁₂, Li_1.5Al_0.5Ge_1.5(PO₄)₃, Li₆PS₅Cl, or Li₅Na₃Nb₂O₁₂.

7. The method of claim 1, wherein the cathode material is characterized by a conductivity ranging from 1.E-6 S/m to 1.E 5 S/m.

8. The method of claim 1, wherein the cathode material is characterized by a C rate ranging from C/100 to 100 C.

9. The method of claim 1, wherein the cathode material is characterized by an XRD peak to total ratio ranging from 0% to 50% crystallinity.

10. The method of claim 1, wherein the cathode material is characterized by an average crystallite size ranging from 0.1 to 100 nm configured in a spatial region.

11. The method of claim 1, wherein the cathode material comprises a surface morphology.

12. The method of claim 1, wherein forming the cathode material comprises subjecting a source material to an energy source maintained in a vacuum environment to decompose the source material via evaporation to cause a deposition of cathode material.

13. The method of claim 1, wherein forming the cathode material comprises a plurality of pillar structures, each of the pillar structure having a base region and an upper region, each of the pillar structures comprising a plurality of smaller particle-like structures, each of the smaller particle like structures being configured within each of the pillar structures.

14. The method of claim 1, wherein the forming the cathode material comprises a plurality of pillar structures, each of the pillar structures having a base region and an upper region, each of the pillar structures comprising a plurality of particle-like structures, each of the particle like structures being configured within each of the pillar structures, each pair of pillar structures having a plurality of irregularly-shaped polyhedral structures provided between the pair of pillar structures.

15. The method of claim 1, wherein the forming of the cathode material comprises forming a plurality of first cone structures and a plurality of second cone structures such that the plurality of first cone structures is inter-digitated with the plurality of second cone structures.

16. The method of claim 1, wherein the cathode material comprises a plurality of discontinuities generally arranged in a direction from a first face of the cathode material to a second face of the cathode material.

17. The method of claim 1, wherein forming the cathode material comprises a plurality of nanotube structures, each of the nanotube structure having a base region and an upper region, and substantially arranged in a direction normal to an upper surface region and a lower surface region of the cathode material.

18. A multilayered thin film solid state battery device, the device comprising:

a substrate member comprising a surface region, the substrate member having a melting point temperature;

an electrode material overlying the surface region;

a cathode material configured as an amorphous structure having an average particle size ranging from 0.05 μ

m to 100 μ

m;

a spatial volume characterized by an external border region of the cathode material;

a diffusivity characterizing the cathode material and having a value ranging from 1.E-18 m²/s to 1.E-12 m²/s;

a void region characterizing the cathode material, the void region being 0.001% to 20% of the spatial volume;

an electrolyte configured overlying the cathode material;

an anode material overlying the electrolyte; and

an energy density of ranging from 100 Watt-hour/liter to 2000 Watt-hour/liter,

wherein the cathode material comprises a plurality of pillar structures, each of the pillar structures having a base region and an upper region, each of the pillar structures comprising a plurality of particle-like structures, each of the particle like structures being configured within each of the pillar structures, each pair of pillar structures having a plurality of irregularly-shaped polyhedral structures provided between the pair of pillar structures.

19. A method of designing and manufacturing a battery device, the method comprising:

providing a first battery cell having a first design, the first design having a first electrode member, a first cathode device characterized by a first structure and a first composition, an electrolyte, and a second electrode member; and

a first energy density value;

determining a first diffusivity value of the cathode device, the first energy density value being directly associated with the first diffusivity value;

adjusting the first cathode device to a plurality of cathode devices numbered from 2 through N, where N is an integer greater than 2, each of the plurality of cathode devices having a diffusivity value numbered from 2 through N;

selecting the diffusivity value having a highest value, in reference to the other diffusivity values, and associating the diffusivity value having the highest value with its cathode device;

designing a second battery cell having a second design, the second design having the cathode device having the highest diffusivity value, the second battery device having a higher energy density than all of the other battery devices having any of the other cathode devices; and

manufacturing the second battery device.