Low-profile battery construct with engineered interfaces

Patent metadata

Field	Value
Publication number	US-2017256759-A1
Application number	US-201615061169-A
Country	US
Kind code	A1
Filing date	Mar 4, 2016
Priority date	Mar 4, 2016
Publication date	Sep 7, 2017
Grant date	—

Abstract

A battery structure includes an anode packaging material having a first textured surface and an anode metal formed on the first textured surface. A separator is formed on the anode metal. A cathode packaging material includes a second textured surface. A cathode metal is formed on the second textured surface. An active cathode paste is formed on the cathode metal and brought into contact with the separator such that any gap is filled with electrolyte.

First claim

What is claims is:

1 . A battery structure, comprising:
an anode packaging material having a first textured surface; anode metal formed on the first textured surface; a separator formed on the anode metal; a cathode packaging material having a second textured surface; a cathode metal formed on the second textured surface; and an active cathode paste formed on the cathode metal and brought into contact with the separator such that any gap is filled with electrolyte.

2 . The battery structure as recited in claim 1 , wherein the anode metal is further textured at an interface with the separator.

3 . The battery structure as recited in claim 2 , wherein the separator includes hydrogel.

4 . The battery structure as recited in claim 1 , wherein at least one of the first textured surface and the second textured surface includes three dimensional shapes.

5 . The battery structure as recited in claim 1 , wherein at least one of the first textured surface and the second textured surface include laser-written grooves.

6 . The battery structure as recited in claim 1 , further comprising a seed layer formed on the anode packaging material wherein the anode metal is formed over the seed layer.

7 . The battery structure as recited in claim 6 , further comprising a transition layer formed on the seed layer wherein the anode metal is formed on the transition layer.

8 . The battery structure as recited in claim 1 , wherein the first textured surface includes a texture pattern and layers of metal are conformally formed on the texture pattern to provide a textured interface for the anode metal that follows the first textured surface.

9 . The battery structure as recited in claim 1 , wherein the second textured surface includes a texture pattern and the cathode metal is conformally formed on the texture pattern to provide a textured interface on an opposite side of the cathode metal from the second textured surface.

10 . A battery structure, comprising:
an active battery region including:
a textured anode metal formed on first textured packaging material;
a hydrogel separator formed on the textured anode metal;
a textured cathode metal formed on second textured packaging material;
a MnO2 paste formed on the textured cathode metal; and
a first battery seal region configured to contain the hydrogel separator outside the active battery region on an anode side; a second battery seal region configured to contain the MnO2 paste outside the active battery region on a cathode side; and an electrolyte disposed in any gap between the hydrogel separator and the MnO2 paste, the gap being filled with electrolyte.

11 . The battery structure as recited in claim 10 , wherein textured anode metal includes three dimensional shapes.

12 . The battery structure as recited in claim 10 , wherein the textured anode metal includes laser-written grooves.

13 . The battery structure as recited in claim 10 , wherein textured cathode metal includes three dimensional shapes.

14 . The battery structure as recited in claim 10 , wherein the first textured packaging material and the second textured packaging material include laser-written grooves.

15 . The battery structure as recited in claim 10 , further comprising:
a seed layer formed between the anode metal and the first textured packaging material; and a transition layer formed on the seed layer wherein the anode metal is formed on the transition layer.

16 . The battery structure as recited in claim 10 , wherein the first textured packaging material includes a texture pattern and layers of metal are conformally formed on the texture pattern to provide a textured interface for the anode metal that follows the first textured surface.

17 . The battery structure as recited in claim 10 , wherein the second textured packaging material includes a texture pattern and the cathode metal is conformally formed on the texture pattern to provide a textured interface on an opposite side of the cathode metal from the texture pattern.

18 . A method for forming a battery structure, comprising:
texturing an anode packaging material to form a first textured surface; depositing one or more metal layers including an anode metal on the first textured surface; forming a separator on the anode metal; texturing a cathode packaging material to form a second textured surface; depositing a cathode metal on the second textured surface; and forming an electrolyte binder paste on the cathode metal, which contacts the separator with any gap being filled with electrolyte.

19 . The method structure as recited in claim 18 , wherein texturing the anode packaging material includes one of laser writing, lithographical patterning or mechanically embossing textural elements.

20 . The method structure as recited in claim 18 , wherein texturing the cathode packaging material includes one of laser writing, lithographical patterning or mechanically embossing textural elements.

Assignees

• IBM

Inventors

• Andry Paul S
• Lauro Paul A
• Nah Jae-Woong
• Narasgond Adinath
• Polastre Robert J
• Webb Bucknell C

Classifications

• H01M4/0426 Primary

  Sputtering · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M4/50

  of manganese · CPC title

• H01M4/0452

  from solutions · CPC title

• H01M4/664

  Ceramic materials · CPC title