Lithium/air batteries with LiPON as separator and protective barrier and method

• US 7,211,351 B2
• Filed: 10/16/2003
• Issued: 05/01/2007
• Est. Priority Date: 10/16/2003
• Status: Expired due to Fees

• Current Assignee: Cymbet Corporation
• Original Assignee: Cymbet Corporation
• Inventors: Klaassen, Jody J.
• Primary Examiner(s): WEINER, LAURA S
• Application Number:
  US10/895,445
• Publication Number:
  US 20050095506A1
• Time in Patent Office: 1,293 Days
• Field of Search: 429/27, 429/28, 429/129, 429/322, 429/245, 429/42, 429/247, 296/235, 427/115, 427/58
• US Class Current: 429/247
• CPC Class Codes: H01M 12/06 with one metallic and one gaseous electrode
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/96 Carbon-based electrodes
• CPC Class Codes: H01M 50/431 Inorganic material
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

A method and apparatus for making lithium/air batteries with LiPON as separator and protective barrier, and the resulting cell(s) and/or battery(s). Some embodiments include an apparatus that includes a lithium anode; a polymer-air cathode; and a LiPON separator between the anode and cathode. In some embodiments, the polymer-air cathode includes a carbon-polyfluoroacrylate material. In some embodiments, the anode overlays a copper anode contact.

Claims

1. An apparatus comprising:

a lithium anode;

a polymer-air cathode;

a LiPON separator between the anode and cathode; and

wherein the apparatus is configured to be activated after assembly by penetrating an electrolyte solution through the cathode.

2. The apparatus of claim 1, wherein the electrolyte solution includes propylene carbonate/LiPF6.

3. The apparatus of claim 1, wherein the apparatus includes a substrate, wherein the lithium anode is formed onto the substrate by electroplating through the LiPON layer, such that the lithium anode is between the substrate and the LiPON layer.

4. The apparatus of claim 3, wherein the substrate includes silicon.

5. The apparatus claim 4, wherein the substrate includes a conductive layer that includes chromium.

6. The apparatus of claim 5, wherein the substrate includes a conductive layer that includes copper between the lithium anode and the chromium.

7. The apparatus of claim 3, wherein the substrate includes metal foil.

8. The apparatus of claim 3, wherein the substrate includes one or more plastics.

9. The apparatus of claim 3, wherein the substrate includes one or more ceramics.

10. An apparatus comprising:

a lithium anode;

a polymer-air cathode;

a LiPON separator between the anode and cathode; and

wherein the polymer-air cathode includes a carbon-polyfluoroacrylate material.

11. The apparatus of claim 10, wherein the anode overlays a copper anode contact.

12. A method comprising:

depositing a LiPON separator on a substrate;

depositing a lithium anode on the substrate through the LiPON separator;

depositing a polymer-air cathode on the separator; and

activating battery functionality after assembly by penetrating an electrolyte solution through the cathode.

13. The method of claim 12, wherein the electrolyte solution includes propylene carbonate/LiPF₆.

14. The method of claim 12, wherein the depositing a lithium anode includes electroplating through the LiPON separator.

15. A method comprising:

depositing a lithium anode on a substrate;

depositing a LiPON separator over the anode;

depositing a polymer-air cathode on the separator; and

wherein the polymer-air cathode includes a carbon-polyfluoroacrylate material.

16. The method of claim 15, wherein the anode is deposited as a layer on a copper anode contact layer.

17. An apparatus comprising:

a LiPON separator on a substrate;

means for depositing a lithium anode through the LiPON separator and on the substrate;

means for depositing a polymer-air cathode on the separator to form a non-activated battery; and

means for activating battery functionality after assembly by penetrating an electrolyte solution through the cathode.

18. The apparatus of claim 17, wherein the electrolyte solution includes propylene carbonate/LiPF₆.

19. The apparatus of claim 17, further comprising

a substrate, wherein the lithium anode is formed onto the substrate by electroplating through the LiPON layer, such that the lithium anode is between the substrate and the LiPON layer.

20. An apparatus comprising:

a lithium anode on a substrate;

means for depositing a LiPON separator over the anode and for depositing a polymer-air cathode on the separator; and

wherein the polymer-air cathode includes a carbon-polyfluoroacrylate material.

21. The apparatus of claim 20, wherein the anode contacts a copper anode contact layer.