Olefin separator free li-ion battery

Patent metadata

Field	Value
Publication number	US-2019058177-A1
Application number	US-201816037895-A
Country	US
Kind code	A1
Filing date	Jul 17, 2018
Priority date	Aug 17, 2017
Publication date	Feb 21, 2019
Grant date	—

Abstract

Implementations of the present disclosure generally relate to separators, high performance electrochemical devices, such as, batteries and capacitors, including the aforementioned separators, and methods for fabricating the same. In one implementation, a method of forming a separator for a battery is provided. The method comprises exposing a metallic material to be deposited on a surface of an electrode structure positioned in a processing region to an evaporation process. The method further comprises flowing a reactive gas into the processing region. The method further comprises reacting the reactive gas and the evaporated metallic material to deposit a ceramic separator layer on the surface of the electrode structure.

First claim

1 . A method of forming a separator fora battery, comprising:
exposing a metallic material to be deposited on a surface of an electrode structure positioned in a processing region to an evaporation process; flowing a reactive gas into the processing region; and reacting the reactive gas and the evaporated metallic material to deposit a ceramic separator layer on the surface of the electrode structure, wherein flowing a reactive gas into the processing region comprises flowing moist oxygen into the processing region.

2 . The method of claim 1 , wherein the metallic material is selected from the group consisting of: aluminum (Al), silver (Ag), chromium (Cr), copper (Cu), indium (In), iron (Fe), magnesium (Mg), nickel (Ni), tin (Sn), ytterbium (Yb), or combinations thereof.

3 . The method of claim 1 , wherein the ceramic separator layer is an aluminum hydroxide oxide layer.

4 . The method of claim 1 , wherein the evaporation process is a thermal evaporation process or an electron beam evaporation process.

5 . The method of claim 1 , wherein the evaporation process comprises exposing the metallic material to a temperature of between 1,300 degrees Celsius and 1,600 degrees Celsius.

6 . The method of claim 1 , wherein the ceramic separator layer is a binder-free ceramic layer.

7 . The method of claim 1 , wherein the ceramic separator layer has a thickness in the range of 1 nanometer and 3,000 nanometers.

8 . The method of claim 7 , wherein the ceramic separator layer has a thickness in the range of 10 nanometers to 500 nanometers.

9 . The method of claim 1 , wherein the ceramic separator layer comprises boehmite.

10 . The method of claim 1 , further comprising:
depositing a ceramic edge coating on an edge of the electrode structure using a wet coating technique.

11 . The method of claim 10 , wherein depositing the ceramic edge coating occurs prior to exposing the metallic material to be deposited on the surface of the electrode structure.

12 . The method of claim 10 , wherein depositing the ceramic edge coating occurs after depositing the ceramic separator layer on the surface of the electrode structure.

13 . The method of claim 1 , wherein the electrode structure is a negative electrode.

14 . The method of claim 1 , wherein the electrode structure is a positive electrode.

15 . The method of claim 1 , further comprising depositing a gel polymer layer on the ceramic separator layer.

16 . A method of forming a battery, comprising:
depositing a ceramic separator layer on a surface of a negative electrode structure, comprising:
exposing a metallic material to be deposited on the surface of the negative electrode structure positioned in a processing region to an evaporation process;
flowing a reactive gas into the processing region; and
reacting the reactive gas and the evaporated metallic material to deposit the ceramic separator layer on the surface of the negative electrode structure, wherein flowing a reactive gas into the processing region comprises flowing moist oxygen into the processing region; and
joining the negative electrode structure with a positive electrode structure with the ceramic separator layer therebetween.

17 . The method of claim 16 , wherein the ceramic separator layer is an aluminum hydroxide oxide layer.

18 . The method of claim 16 , wherein the evaporation process is a thermal evaporation process or an electron beam evaporation process.

19 . A method of forming a battery, comprising:
depositing a ceramic separator layer on a surface of a positive electrode structure, comprising:
exposing a metallic material to be deposited on the surface of the positive electrode structure positioned in a processing region to an evaporation process;
flowing a reactive gas into the processing region; and
reacting the reactive gas and the evaporated metallic material to deposit the ceramic separator layer on the surface of the positive electrode structure, wherein flowing a reactive gas into the processing region comprises flowing moist oxygen into the processing region; and
joining the positive electrode structure with a negative electrode structure with the ceramic separator layer therebetween.

20 . The method of claim 19 , wherein the ceramic separator layer is an aluminum hydroxide oxide layer.

Assignees

• Applied Materials Inc

Inventors

• Herle Subramanya P

Classifications

• H01M10/058 Primary

  Construction or manufacture · CPC title

• C23C14/081

  of aluminium, magnesium or beryllium · CPC title

• H01G11/84

  Processes for the manufacture of hybrid or EDL capacitors, or components thereof · CPC title

• H01G9/02

  Diaphragms; Separators · CPC title

• C23C14/28

  by wave energy or particle radiation (C23C14/32 - C23C14/48 take precedence) · CPC title