Hybrid thin-film battery

• US 8,431,264 B2
• Filed: 07/25/2008
• Issued: 04/30/2013
• Est. Priority Date: 08/09/2002
• Status: Active Grant

• Current Assignee: Sapurast Research LLC
• Original Assignee: Infinite Power Solutions, Inc. (Apple Inc.)
• Inventors: Neudecker, Bernd J., Snyder, Shawn W.
• Primary Examiner(s): Walls, Cynthia
• Application Number:
  US12/179,701
• Publication Number:
  US 20080286651A1
• Time in Patent Office: 1,740 Days
• Field of Search: None
• US Class Current: 429/137
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/4235 Safety or regulating additives or arrangements in electrodes, separators or electrolyte H01M10/4242 takes precedence
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2300/0068 inorganic
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0457 from dispersions or suspensions; Electrophoresis
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/405 Alloys based on lithium
• 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 4/525 of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• 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: Y10T 29/49115 including coating or impregnating

Abstract

An electrochemical device is claimed and disclosed wherein certain embodiments have a cathode greater than about 4 μm and less than about 200 μm thick; a thin electrolyte less than about 10 μm thick; and an anode less than about 30 μm thick. Another claimed and disclosed electrochemical device includes a cathode greater than about 0.5 μm and less than about 200 μm thick; a thin electrolyte less than about 10 μm thick; and an anode less than about 30 μm thick, wherein the cathode is fabricated by a non-vapor phase deposition method. A non-vacuum deposited cathode may be rechargeable or non-rechargeable. The cathode may be made of CF_x (carbon fluoride) material, wherein, for example, 0<x<4. The electrochemical device may also include a substrate, a current collector, an anode current collector, encapsulation and a moderating layer.

Claims

1. An electrochemical device comprising:

a non-vapor phase deposited positive cathode greater than about 0.5 μ

m and less than about 200 μ

m thick;

a layer on the positive cathode;

a vapor phase deposited electrolyte less than about 10 μ

m thick over the layer on said positive cathode;

a negative anode less than about 30 μ

m thick is positioned directly on the vapor phase deposited electrolyte; and

wherein said electrochemical device is non-rechargeable.

4. The electrochemical device of claim 1 comprising a non-rechargeable cathode consisting of CF_X material.

5. The electrochemical device of claim 4, wherein x falls within the range of 0 to 4.

6. The electrochemical device of claim 1 further comprising:

a positive cathode greater than about 4 μ

m and less than about 200 μ

m thick.

10. The electrochemical device of claim 6 comprising a non-rechargeable cathode consisting of CF_X material.

14. The electrochemical device of claim 1, wherein the layer is absorbed into the cathode.

2. An electrochemical device comprising:

a positive cathode greater than about 4 μ

m and less than about 200 μ

m thick;

an electrolyte less than about 10 μ

m thick;

a negative anode less than about 30 μ

m thick; and

wherein said cathode comprises CF_X material.

3. The electrochemical device of claim 2 wherein x falls within the range of 0 to 4.

7. The electrochemical device of claim 3 comprising a non-rechargeable cathode consisting of CF_X material.

8. An electrochemical device comprising:

a non-vapor phase deposited cathode;

an anode; and

a vapor phase deposited electrolyte less than about 10 μ

m thick and positioned directly on the anode;

a layer between the cathode and the electrolyte; and

wherein said electrochemical device is non-rechargeable.

15. The electrochemical device of claim 8, wherein the layer is absorbed into the cathode.

9. An electrochemical device comprising:

a non-vapor phase deposited cathode;

an anode; and

a vapor phase deposited electrolyte less than about 10 μ

m thick and positioned directly on the anode;

a layer between the cathode and the electrolyte; and

wherein said cathode comprises CF_X material, and wherein x falls within the range of 0 to 4.

16. The electrochemical device of claim 9, wherein the layer is absorbed into the cathode.

11. A method of manufacturing an electrochemical device comprising:

depositing a positive cathode comprising CFX that is greater than about 0.5 μ

m and less than about 200 μ

m thick;

depositing an electrolyte that is less than about 10 μ

m thick;

depositing a negative anode that is less than about 30 μ

m thick; and

depositing said positive cathode by a non-vapor phase deposition process.

12. The method of claim 11 wherein x falls within the range of 0 to 4.

13. A method of manufacturing an electrochemical device comprising:

depositing a cathode comprising CF_X using a non-vapor phase deposition process;

depositing an electrolyte that is less than about 10 μ

m thick; and

depositing an anode.