Method for manufacturing ultra-capacity battery

Patent metadata

Field	Value
Publication number	US-2019074141-A1
Application number	US-201816179456-A
Country	US
Kind code	A1
Filing date	Nov 2, 2018
Priority date	Dec 11, 2015
Publication date	Mar 7, 2019
Grant date	—

Abstract

A method for manufacturing an ultra-capacity battery includes providing cathodes and anodes. Providing the cathodes includes providing a first substrate having a first surface and a second surface opposite the first surface, forming a plurality of first combs perpendicular to the first surface of the first substrate and arranged at a first interval along a first direction, forming a graphene layer on the first combs and on the first surface of the first substrate. Providing the anodes includes providing a second substrate having a first surface and a second surface, forming a patterned insulating film on the first surface of the second substrate exposing a portion of the first surface of the second substrate, etching the exposed portion of the first surface of the second substrate to form a body portion and a plurality of second combs perpendicular to the body portion.

First claim

What is claimed is:

1 . A method for manufacturing an ultra-capacity battery comprising:
preparing a plurality of cathodes and a plurality of anodes, wherein: preparing the cathodes comprises:
providing a first substrate having a first surface and a second surface opposite the first surface;
forming a plurality of first combs perpendicular to the first surface of the first substrate and arranged at a first interval along a first direction;
forming a graphene layer on the first combs and on the first surface of the first substrate; and
preparing the anodes comprises:
providing a second substrate having a first surface and a second surface;
forming a patterned insulating film on the first surface of the second substrate exposing a portion of the first surface of the second substrate;
etching the exposed portion of the first surface of the second substrate to form a body portion and a plurality of second combs perpendicular to the body portion, the second combs being arranged at a second interval along a second direction, the first and second direction being parallel to each other;
providing a hermetically sealed container enclosing the cathodes and the anodes, wherein the first combs and the second combs are interspersed between each other and have an air gap between them; and filling the container and the air gap with an electrolyte solution.

2 . The method of claim 1 , wherein forming the first combs comprises:
forming a first hardmask layer on the first surface of the first substrate; patterning the first hardmask layer to form a plurality of first openings; filling the first openings with a first comb material to form the first combs; and removing the first hardmask layer.

3 . The method of claim 2 , further comprising:
forming a second hardmask layer on the second surface of the first substrate; patterning the first hardmask layer to form a plurality of second openings; filling the second openings with a third comb material to form a plurality of third combs; and removing the second hardmask layer.

4 . The method of claim 3 , further comprising forming the graphene layer on the third combs and on the second surface of the first substrate.

5 . The method of claim 4 , wherein the graphene layer comprises a multilayer graphene, or a mixture of graphene and graphite.

6 . The method of claim 3 , wherein a number of the third combs is equal to a number of the first combs.

7 . The method of claim 3 , wherein the first substrate, the first combs, and the third combs each comprise a material selected from the group consisting of Cu, Si, SiC and Sn.

8 . The method of claim 1 , wherein forming the patterned insulating film on the first surface of the second substrate also comprises forming the patterned insulating film on the second surface of the second substrate exposing a portion of the second surface of the second substrate, and the method further comprising:
etching the exposed portion of the second surface of the second substrate to a depth to form a plurality of fourth combs extending perpendicularly to the body portion.

9 . The method of claim 8 , wherein a number of the fourth combs is equal to a number of the second combs.

Assignees

• Semiconductor Mfg Int Shanghai Corp
• Semiconductor Mfg Int Beijing Corp

Inventors

• Zhou Ming

Classifications

• H01G11/26 Primary

  characterised by their structure, e.g. multi-layered, porosity or surface features · CPC title

• H01G11/36

  Nanostructures, e.g. nanofibres, nanotubes or fullerenes · CPC title

• H01G11/24

  characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosity; characterised by the structural features of powders or particles used therefor · CPC title

• H01G11/74

  Terminals, e.g. extensions of current collectors · CPC title

• H01G11/70

  characterised by their structure · CPC title