High silica content substrate such as for use in thin-film battery

Patent metadata

Field	Value
Publication number	US-9634349-B2
Application number	US-201514684627-A
Country	US
Kind code	B2
Filing date	Apr 13, 2015
Priority date	Apr 13, 2015
Publication date	Apr 25, 2017
Grant date	Apr 25, 2017

Abstract

A high silica content substrate, such as for a thin-film battery, is provided. The substrate has a high silica content, such as over 90% by weight silica, and is thin, for example less than 500 μm. The substrate may include a surface with a topography or profile that facilitates bonding with a coating layer, such as a coating of an electrochemical battery material. The high silica content substrate may be flexible, have high temperature resistance, high strength and/or be non-reactive. The substrate may be suitable for use in the high temperature environments used in many chemical deposition or formation processes, such as electrochemical battery material formation processes.

First claim

What is claimed is:

1. An electrochemical battery assembly comprising:
(A) a high silica content substrate comprising:
(i) a first major surface;
(i) a second major surface opposite the first major surface;
(iii) at least 90% SiO 2 by weight;
(iv) an average thickness between the first major surface and the second major surface of less than 500 μm; and
(v) a minimum dimension orthogonal to the thickness that is less than 100 m and greater than 1 mm;
(vi) a width and a length that are each less than 100 m and greater than 1 mm;
(vii) an outer perimeter surface extending between the first major surface and the second major surface;
(viii) a first group of a plurality of raised elongate features formed in the first major surface and extending in the direction of the width, wherein each raised elongate feature of the first group has a length and a width and the length is at least ten times larger than width, wherein the width of each elongate feature of the first group is between 10 mm and 2 μm; and
(ix) a second group of a plurality of raised elongate features formed in the first major surface and extending in the direction of the length, wherein at least some of the raised elongate features of the second group intersect raised elongate features of the first group, wherein each raised elongate feature of the second group has a length and a width and the length is at least ten times larger than width, wherein the width of each raised elongate feature of the second group is between 10 mm and 2 μm;
(x) wherein at least some of the raised elongate features of the first group and of the second group extend from the surface a distance of at least 2 μm beyond a lowest portion of the first major surface; and
(xi) wherein the surface area of the first major surface is at least 1.5 times the area of the cross-sectional shape defined by the outer perimeter surface of the substrate; and

(B) a first layer of a first battery material bonded to the first major surface of the substrate, wherein the first battery material is one of a cathode material, an anode material, an electrolyte and a current collector material.

2. The electrochemical battery assembly of claim 1 , wherein the first battery material is a current collector material, the electrochemical battery assembly further comprising:
a second layer of a second battery material bonded to the first layer, wherein the second battery material is one of a cathode material and an anode material;
a third layer of a third battery material bonded to the second layer, wherein the third battery material is an electrolyte material;
a fourth layer of a fourth battery material bonded to the third layer, wherein the fourth battery material is one of a cathode material and an anode material; and
a fifth layer of a current collector material bonded to the fourth layer.

3. The electrochemical battery assembly of claim 2 , having a total thickness measured between opposing outermost surfaces of the battery assembly in a direction perpendicular to the first major surface, wherein the thickness of the substrate accounts for less than 60% of the total thickness of the battery assembly.

4. The electrochemical battery assembly of claim 2 , wherein the cathode material includes at least one of LiCoO 2 , LiMn 2 O 4 LiFePO 4 , Li sulfur, Li mixed metal phosphates, and Li mixed metal oxides, wherein the anode material includes at least one of graphite, LiNiMnCoO 2 , Li 4 Ti 5 O 12 , an alloy of tin and cobalt and silicon-carbon materials, wherein the electrolyte material is lithium phosphorus oxynitride.

5. The electrochemical battery assembly of claim 4 , wherein the substrate is nonreactive with the cathode material at voltages from 0.1 V to 5.5 V.

6. The electrochemical battery assembly of claim 1 , wherein the substrate consists of at least 99% SiO 2 by weight.

7. The electrochemical battery assembly of claim 1 , wherein the substrate bends to a radius of curvature of at least 500 mm without fracture when at room temperature of 25° C.

8. The electrochemical battery assembly of claim 1 , wherein the cross-sectional shape defined by the outer perimeter surface of the substrate is non-circular.

9. The electrochemical battery assembly of claim 1 , wherein the cross-sectional shape defined by the outer perimeter surface of the substrate is rectilinear.

10. The electrochemical battery assembly of claim 1 , wherein the substrate is a fused quartz material.

11. The electrochemical battery assembly of claim 1 , wherein the substrate is formed from a glass of (SiO 2 ) 1-x-y .M′M″ y composition, where either or both of M′ and M″ is an element, dopant, or substitution, which may be in an oxide form, or combination thereof, or is omitted, and where the sum of x plus y is less than 1.

12. The electrochemical battery assembly of claim 1 , wherein the substrate has a thickness less than 250 μm.

13. The electrochemical battery assembly of claim 1 , wherein the substrate has a softening point temperature greater than 700° C.

14. The electrochemical battery assembly of claim 1 , wherein the substrate has a low coefficient of thermal expansion, that being less than 10×10 −7 /° C. in the temperature range of about 50° C. to 300° C. thereby facilitating dimensional stability to the substrate during formation of the first battery material on the substrate.

15. An assembly comprising:
(A) a substrate comprising:
(i) a first major surface;
(ii) a second major surface opposite the first major surface; and
(iii) at least 99% by weight silica, wherein the substrate is formed from a glass of (SiO 2 ) 1-x-y .M′ x M″ y composition, where either or both of M′ and M″ is an element, dopant, or substitution, which may be in an oxide form, or combination thereof, or is omitted, and where the sum of x plus y is less than 1;
(iv) wherein the first major surface comprises a plurality raised features and a plurality of recessed features, wherein at least some of the raised features extend from the surface a distance of at least 10 angstroms further than the recessed features;
(v) an outer perimeter surface extending between the first major surface and the second major surface, wherein the plurality of raised and recessed features comprises:
(a) a first group of a plurality of raised elongate features formed in the first major surface and extending in the direction of the width, wherein each raised elongate feature of the first group has a length and a width and the length is at least ten times larger than width, wherein the width of each raised elongate feature of the first group is between 10 mm and 2 μm; and
(b) a second group of a plurality of raised elongate features formed in the first major surface and extending in the direction of the length, wherein at least some of the raised elongate features of the second group intersect a raised elongate feature of the first group, wherein each raised elongate feature of the second group has a length and a width and the length is at least ten times larger than width, wherein the width of each elongate feature of the second group is between 10 mm and 2 μm;
(c) wherein at least some of the raised features of the first group and of the second group extend from the surface a distance of at least 1 μm beyond the lowest portion of the first major surface;

(vi) wherein the surface area of the first major surface is at least 1.5 times the area of the cross-sectional shape defined by the outer perimeter surface of the substrate; and

(B) a coating positioned directly on the first major surface such that an inner surface of the coating contacts the first major surface, whe

Assignees

• Corning Inc

Inventors

• Hawtof Daniel Warren
• Lal Archit

Classifications

• H01M10/0525

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

• H01M10/0436 Primary

  Small-sized flat cells or batteries for portable equipment · CPC title

• H01M6/40

  Printed batteries {, e.g. thin film batteries} · CPC title

• H01M4/5825

  Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines · CPC title

• 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