Three-dimensional thin film battery

Patent metadata

Field	Value
Publication number	US-2017237124-A1
Application number	US-201515504590-A
Country	US
Kind code	A1
Filing date	Aug 27, 2015
Priority date	Aug 27, 2014
Publication date	Aug 17, 2017
Grant date	—

Abstract

A thin film battery may comprise: a substrate comprising a substrate surface; a first current collector (FCC) layer formed on the substrate surface, the FCC layer having a first FCC surface and a second FCC surface and wherein the first FCC surface is in contact with the substrate and the second FCC surface is a first three-dimensional surface; a first electrode layer deposited on the first current collector, and an electrolyte layer deposited on the first electrode layer; wherein the interface between the first electrode layer and the electrolyte layer is a second three-dimensional surface roughly in conformity with the first three-dimensional surface. In embodiments, the substrate surface is a third three-dimensional surface and the first three-dimensional surface is roughly in conformity with the third three-dimensional surface. One of the first or the third three-dimensional surfaces may be formed by a laser ablation patterning process.

First claim

1 . A thin film battery, comprising:
a substrate comprising a substrate surface; a first current collector (FCC) layer formed on said substrate surface, said FCC layer having a first FCC surface and a second FCC surface and wherein said first FCC surface is in contact with said substrate and said second FCC surface is a first three-dimensional surface; a first electrode layer deposited on said first current collector, and an electrolyte layer deposited on said first electrode layer; wherein the interface between said first electrode layer and said electrolyte layer is a second three-dimensional surface roughly in conformity with said first three-dimensional surface.

2 . The thin film battery of claim 1 , wherein said first three-dimensional surface comprises an array of patterned shapes.

3 . The thin film battery of claim 1 , wherein said substrate surface is a third three-dimensional surface and said first three-dimensional surface is roughly in conformity with said third three-dimensional surface.

4 . The thin film battery of claim 1 , further comprising:
a second electrode layer deposited on said electrolyte layer; and a second current collector (SCC) layer deposited on said second electrode layer; wherein said electrolyte layer is deposited on said first electrode layer and wherein the interface between said second electrode layer and said electrolyte layer is a fourth three-dimensional surface roughly in conformity with said first three-dimensional surface.

5 . The thin film battery of claim 4 , wherein the interface between said second electrode layer and said SCC layer is a fifth three-dimensional surface roughly in conformity with said fourth three-dimensional surface.

6 . The thin film battery of claim 1 , wherein said FCC layer is a cathode current collector layer and said first electrode layer is a cathode layer.

7 . The thin film battery of claim 1 , wherein said FCC layer is an anode current collector layer and said first electrode layer is an anode layer.

8 . The thin film battery of claim 4 , wherein said FCC layer is a cathode current collector layer and said first electrode layer is a cathode layer, and wherein said second electrode layer is an anode and said SCC layer is an anode current collector layer.

9 . The thin film battery of claim 4 , wherein said FCC layer is an anode current collector layer and said first electrode layer is an anode layer, and wherein said second electrode layer is a cathode and said SCC layer is a cathode current collector layer.

10 . A method of manufacturing a thin film battery, comprising:
providing a substrate; three-dimensionally restructuring the surface of said substrate to form a restructured substrate surface; depositing a first current collector (FCC) layer on said restructured substrate surface; depositing an electrode layer on said FCC layer; and depositing an electrolyte layer on said electrode layer; wherein the interface between said electrode layer and said electrolyte layer is a first three-dimensional surface roughly in conformity with said restructured substrate surface.

11 . The method of claim 10 , further comprising:
depositing a second electrode layer on said electrolyte layer; wherein the interface between said electrolyte layer and said second electrode layer is a second three-dimensional surface roughly in conformity with said restructured substrate surface.

12 . A method of manufacturing a thin film battery, comprising:
providing a substrate; depositing a first current collector (FCC) layer on the surface of said substrate; three-dimensionally restructuring the surface of said FCC layer to form a restructured FCC surface; depositing a first electrode layer on said restructured FCC surface; and depositing an electrolyte layer on said first electrode layer; wherein the interface between said first electrode layer and said electrolyte layer is a first three-dimensional surface roughly in conformity with said restructured FCC surface.

13 . The method of claim 10 , wherein said three-dimensionally restructuring comprises a laser ablation patterning process.

14 . The method of claim 12 , wherein said three-dimensionally restructuring comprises a mechanical roughening process.

15 . The method of claim 12 , further comprising:
depositing a second electrode layer on said electrolyte layer; wherein the interface between said electrolyte layer and said second electrode layer is a second three-dimensional surface roughly in conformity with said restructured first current collector surface.

16 . The method of claim 12 , wherein said three-dimensionally restructuring comprises a laser ablation patterning process.

Assignees

• Applied Materials Inc

Inventors

• Song Daoying
• Kwak Byung Sung Leo

Classifications

• H01M4/525

  of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy · CPC title

• H01M10/0585 Primary

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M4/1395

  of electrodes based on metals, Si or alloys · CPC title

• H01M10/0562

  Solid materials · CPC title

• H01M4/1391

  of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx · CPC title