Lithium anode device stack manufacturing

Patent metadata

Field	Value
Publication number	US-2019088987-A1
Application number	US-201816129002-A
Country	US
Kind code	A1
Filing date	Sep 12, 2018
Priority date	Sep 21, 2017
Publication date	Mar 21, 2019
Grant date	—

Abstract

Metal electrodes, more specifically lithium-containing anodes, high performance electrochemical devices, such as secondary batteries, including the aforementioned lithium-containing electrodes, and methods for fabricating the same are provided. In one implementation, an anode electrode structure is provided. The anode electrode structure comprises a current collector comprising copper, a lithium metal film formed on the current collector, a copper film formed on the lithium metal film, and a protective film formed on the copper film. The protective film is a lithium-ion conducting film selected from the group comprising lithium-ion conducting ceramic, a lithium-ion conducting glass, or ion conducting liquid crystal.

First claim

1 . An anode electrode structure, comprising:
a current collector comprising copper; a lithium metal film formed on the current collector; a metal film formed on the lithium metal film; and a protective film formed on the metal film,
wherein the protective film is a lithium-ion conducting film selected from the group comprising lithium-ion conducting ceramic, lithium-ion conducting glass, lithium-ion conducting polymer, lithium-ion conducting liquid crystal, or combinations thereof, and
wherein the metal film is selected from a copper film, a bismuth film, a tin film, or combinations thereof.

2 . The anode electrode structure of claim 1 , wherein the copper film has a thickness between about 5 nanometers and about 40 nanometers.

3 . The anode electrode structure of claim 2 , wherein the copper film has a thickness between about 10 nanometers and about 20 nanometers.

4 . The anode electrode structure of claim 2 , wherein the lithium-ion conducting film comprises one or more of aluminum oxide (Al 2 O 3 ), LiPON, Li 7 La 3 Zr 2 O 12 (LLZO), Li 2 S—P 2 S 5 , Li 10 GeP 2 S 12 , Li 3 PS 4 , (1−x)LiI-(x)Li 4 SnS 4 , xLiI-(1−x)Li 4 SnS 4 , (1−x)LiI-(x)Li 4 SnS 4 , (x)LiI-(1−x)Li 4 SnS 4 ), wherein 0<x<1.

5 . The anode electrode structure of claim 2 , wherein the lithium metal film has a thickness between about 1 micrometers and about 20 micrometers.

6 . The anode electrode structure of claim 5 , wherein the current collector has a thickness between about 2 micrometers and about 8 micrometers.

7 . The anode electrode structure of claim 1 , wherein the current collector comprises:
a first nickel or chromium containing film; a copper film formed on the first nickel or chromium containing film and having a thickness between about 50 nanometers and about 500 nanometers; and a second nickel or chromium containing film formed on the copper film and having a thickness between about 20 nanometers and about 50 nanometers.

8 . The anode electrode structure of claim 1 , wherein the current collector comprises:
a polyethylene terephthalate (PET) polymer substrate; and a copper film formed on the PET polymer substrate.

9 . An anode electrode structure, comprising:
a current collector comprising copper; a silicon graphite anode formed on the current collector; a film of lithium metal formed on the silicon graphite anode; and a protective film formed on the film of lithium metal, wherein the protective film is a lithium-ion conducting film selected from the group comprising lithium-ion conducting ceramic, lithium-ion conducting glass, lithium-ion conducting polymer, lithium-ion conducting liquid crystal, or combinations thereof.

10 . The anode electrode structure of claim 9 , wherein the lithium-ion conducting film comprises one or more of aluminum oxide (Al 2 O 3 ), LiPON, Li 7 La 3 Zr 2 O 12 (LLZO), Li 2 S—P 2 S 5 , Li 10 GeP 2 S 12 , Li 3 PS 4 , (1−x)LiI-(x)Li 4 SnS 4 , xLiI-(1−x)Li 4 SnS 4 , (1−x)LiI-(x)Li 4 SnS 4 , (x)LiI-(1−x)Li 4 SnS 4 ), wherein 0<x<1.

11 . The anode electrode structure of claim 9 , wherein the film of lithium metal has a thickness between about 1 micrometers and about 20 micrometers.

12 . The anode electrode structure of claim 11 , wherein the current collector has a thickness between about 2 micrometers and about 8 micrometers.

13 . The anode electrode structure of claim 9 , wherein the current collector comprises:
a first nickel or chromium containing film; a copper film formed on the first nickel or chromium containing film and having a thickness between about 50 nanometers and about 500 nanometers; and a second nickel or chromium containing film formed on the copper film and having a thickness between about 20 nanometers and about 50 nanometers.

14 . The anode electrode structure of claim 9 , wherein the current collector comprises:
a polyethylene terephthalate (PET) polymer substrate; and a copper film formed on the PET polymer substrate.

15 . A method, comprising:
forming a lithium metal film on a current collector, wherein the current collector comprises copper; forming a metal film on the lithium metal film, wherein the metal film is selected from a copper film, a bismuth film, a tin film, or combinations thereof; and forming a protective film formed on the metal film, wherein the protective film is a lithium-ion conducting film selected from the group comprising lithium-ion conducting ceramic, lithium-ion conducting glass, or ion conducting liquid crystal.

16 . The method of claim 15 , wherein the copper film has a thickness between about 5 nanometers and about 40 nanometers.

17 . The method of claim 16 , wherein the copper film has a thickness between about 10 nanometers and about 20 nanometers.

18 . The method of claim 15 , wherein the current collector has a thickness between about 2 micrometers and about 8 micrometers.

19 . The method of claim 15 , wherein the current collector comprises:
a first nickel or chromium containing film; a copper film formed on the first nickel or chromium containing film and having a thickness between about 50 nanometers and about 500 nanometers; and a second nickel or chromium containing film formed on the copper film and having a thickness between about 20 nanometers and about 50 nanometers.

20 . The method of claim 15 , wherein the current collector comprises:
a polyethylene terephthalate (PET) polymer substrate; and a copper film formed on the PET polymer substrate, wherein the copper film is deposited via a physical vapor deposition process.

Assignees

• Applied Materials Inc

Inventors

• Herle Subramanya P

Classifications

• H01M10/0431

  Cells with wound or folded electrodes (H01M10/045 takes precedence) · CPC title

• H01M4/667

  in the form of layers, e.g. coatings · CPC title

• H01M10/052

  Li-accumulators · CPC title

• H01M4/661

  Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence) · CPC title

• H01M10/0525 Primary

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title