Three-dimensional batteries and methods of manufacturing the same

Patent metadata

Field	Value
Publication number	US-9761901-B2
Application number	US-201514638410-A
Country	US
Kind code	B2
Filing date	Mar 4, 2015
Priority date	Jan 12, 2007
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

Various methods and apparatus relating to three-dimensional battery structures and methods of manufacturing them are disclosed and claimed. In certain embodiments, a three-dimensional battery comprises a battery enclosure, and a first structural layer within the battery enclosure, where the first structural layer has a first surface, and a first plurality of conductive protrusions extend from the first surface. A first plurality of electrodes is located within the battery enclosure, where the first plurality of electrodes includes a plurality of cathodes and a plurality of anodes, and wherein the first plurality of electrodes includes a second plurality of electrodes selected from the first plurality of electrodes, each of the second plurality of electrodes being in contact with the outer surface of one of said first plurality of conductive protrusions. Some embodiments relate to processes of manufacturing energy storage devices with or without the use of a backbone structure or layer.

First claim

What is claimed is:

1. A process for preparing a three-dimensional non-aqueous battery, comprising:
forming a plurality of anode backbone structures and a plurality cathode backbone structures on a surface of a first structural layer, wherein each of the anode backbone structures and the cathode backbone structures comprises silicon, is connected to the surface of the first structural layer, and protrudes at least 50 microns from the surface of the first structural layer,
forming a plurality of anodes on the anode backbone structures,
forming a plurality of cathodes on the cathode backbone structures, the cathodes being separated from the anodes by gaps, and
depositing a porous separator material in the gaps between the anodes and the cathodes.

2. The process of claim 1 wherein the porous separator material is deposited by electrophoretic deposition.

3. The process of claim 1 wherein the plurality of cathodes are formed by electrophoretically depositing a cathode material on the plurality of cathodes.

4. The process of claim 1 wherein the anode and cathode backbone structures comprise fins protruding at least 50 microns from the surface of the first structural layer.

5. The process of claim 1 wherein the anode and cathode backbone structures comprise fins protruding at least 50 microns from the surface of the first structural layer and having a thickness less than 20 microns.

6. The process of claim 1 wherein the anode and cathode backbone structures comprise pillars protruding at least 50 microns from the surface of the first structural layer.

7. The process of claim 1 wherein the anode and cathode backbone structures comprise cylindrical pillars protruding at least 50microns from the surface of the first structural layer.

8. The process of claim 1 , wherein forming the anodes comprises depositing a layer of an anodically active material onto the outer surface of the anode backbone structures.

9. The process of claim 1 , wherein forming the cathodes comprises depositing a layer of an cathodically active material onto the outer surface of the cathode backbone structures.

10. The process of claim 1 wherein the anode and cathode backbone structures have an aspect ratio of approximately 2.5:1 to 500:1.

11. The process of claim 1 wherein each of the anodes is associated a current collector to form a non-planar active battery component.

12. The process of claim 1 wherein each of the cathodes is associated a current collector to form a non-planar active battery component.

13. The process of claim 1 wherein each of the anodes has a thickness of 5 to 200 μM.

14. The process of claim 1 wherein each of the anodes has a thickness of 10 to 150 μM.

15. The process of claim 1 wherein each of the cathodes has a thickness of 5 to 200 μM.

16. The process of claim 1 wherein each of the cathodes has a thickness of 10 to 150 μM.

17. The process of claim 1 wherein each of the anodes and the cathodes has a thickness of 10 to 150 μM and the first cathode has a thickness of 10 to 150 μM.

Assignees

• Enovix Corp

Inventors

• Rust Iii Harrold J
• Lahiiri Ashok
• Ramasubramanian Murali
• Spotnitz Robert M

Classifications

• H01M4/0457

  from dispersions or suspensions; Electrophoresis · CPC title

• H01M4/0426

  Sputtering · CPC title

• H01M4/0438

  by electrochemical processing (electroless electrochemical plating C23C18/54) · CPC title

• H01M4/0402

  Methods of deposition of the material · CPC title

• H01M10/0472 Primary

  Vertically superposed cells with vertically disposed plates · CPC title