Graphene application in battery

Patent metadata

Field	Value
Publication number	US-9722254-B2
Application number	US-201514810151-A
Country	US
Kind code	B2
Filing date	Jul 27, 2015
Priority date	Jul 27, 2015
Publication date	Aug 1, 2017
Grant date	Aug 1, 2017

Abstract

This disclosure relates to a battery and a method for its manufacture. The method of manufacture may include forming a cathode layer proximate to a cathode current collector. The method further includes forming an electrolyte layer proximate to the cathode layer and an anode layer proximate to the electrolyte layer. The method additionally includes forming an anode current collector layer proximate to the anode layer. At least one of the cathode current collector layer or the anode current collector layer includes a plurality of graphene monolayers. The method yet further includes determining a stepped arrangement of the graphene monolayers; and patterning at least a portion of the plurality of graphene monolayers according to the stepped arrangement.

First claim

What is claimed is:

1. A method of manufacturing a battery, the method comprising:
forming a cathode layer proximate to a cathode current collector;
forming an electrolyte layer proximate to the cathode layer;
forming an anode layer proximate to the electrolyte layer;
forming an anode current collector layer proximate to the anode layer, wherein at least one of the cathode current collector layer or the anode current collector layer comprises a plurality of graphene monolayers;
determining a stepped arrangement of the graphene monolayers; and
patterning at least a portion of the plurality of graphene monolayers according to the stepped arrangement.

2. The method of claim 1 , wherein the plurality of graphene monolayers is initially formed proximate to a substrate comprising copper foil.

3. The method of claim 1 , wherein the stepped arrangement provides a higher surface area to volume ratio at an interface between a patterned portion of the plurality of graphene monolayers and at least one of the cathode layer or the anode layer compared to a surface area to volume ratio at an interface between an unpatterned portion of the plurality of graphene monolayers and the at least one of the cathode layer or the anode layer.

4. The method of claim 3 , wherein determining the stepped arrangement of the graphene monolayers comprises determining a desired surface area to volume ratio at the interface between the patterned portion of the plurality of graphene monolayers and at least one of the cathode layer or the anode layer.

5. The method of claim 4 , wherein determining the desired surface area to volume ratio at the interface comprises calculating, using a computer, the desired surface area to volume ratio based at least on a desired current density of the battery during at least one of a charge mode or a discharge mode.

6. The method of claim 1 , wherein patterning the portion of the plurality of graphene monolayers comprises forming the stepped arrangement via a process comprising electron beam lithography and etching.

7. The method of claim 1 , wherein patterning the portion of the plurality of graphene monolayers comprises forming the stepped arrangement via a nanoimprint lithography process.

8. The method of claim 1 , wherein patterning the portion of the plurality of graphene monolayers comprises selectively removing the portion of the plurality of graphene monolayers via a lithographic process.

9. The method of claim 1 , wherein at least one surface of the battery is curved with respect to an axis substantially perpendicular to the plurality of graphene monolayers.

10. The method of claim 1 , wherein determining the stepped arrangement of the graphene monolayers comprises determining a desired curved shape of the plurality of graphene monolayers.

11. The method of claim 1 , wherein determining the stepped arrangement of the graphene monolayers comprises determining a desired contact resistance of the at least one cathode current collector layer or the at least one anode current collector layer.

12. The method of claim 1 , wherein determining the stepped arrangement of the graphene monolayers comprises determining a desired current density of the battery during at least one of a charge mode or a discharge mode.

13. The method of claim 1 , wherein the battery comprises at least one of a lithium-ion battery or a lithium-polymer battery.

14. The method of claim 1 , wherein the cathode layer comprises lithium cobalt oxide (LiCoO 2 ), wherein the anode layer comprises lithium metal (Li), and wherein the electrolyte layer comprises lithium phosphorous oxynitride (LiPON).

15. A battery comprising:
a cathode layer proximate to a cathode current collector layer;
an electrolyte layer proximate to the cathode layer;
an anode layer proximate to the electrolyte layer; and
an anode current collector layer proximate to the anode layer, wherein at least one of the cathode current collector layer or the anode current collector layer comprises a plurality of graphene monolayers having a stepped arrangement, wherein the stepped arrangement provides a higher surface area to volume ratio at an interface between a patterned portion of the plurality of graphene monolayers and at least one of the cathode layer or the anode layer compared to an interface between an unpatterned portion of the plurality of graphene monolayers and the at least one of the cathode layer or the anode layer, wherein at least one surface of the battery is curved with respect to an axis substantially perpendicular to the plurality of graphene monolayers.

16. The battery of claim 15 , wherein the battery comprises at least one of a lithium-ion battery or a lithium-polymer battery.

17. The battery of claim 15 , wherein the cathode layer comprises lithium cobalt oxide (LiCoO 2 ).

18. The battery of claim 15 , wherein the anode layer comprises lithium metal (Li).

19. The battery of claim 15 , wherein the electrolyte layer comprises lithium phosphorous oxynitride (LiPON).

Assignees

• X Dev Llc

Inventors

• Bhardwaj Ramesh C

Classifications

• H01M10/0525

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

• H01M4/78 Primary

  Shapes other than plane or cylindrical, e.g. helical · CPC title

• H01M4/667

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

• H01M10/0562

  Solid materials · CPC title

• H01M4/382

  Lithium (H01M4/405 takes precedence) · CPC title