Solid state battery fabrication

Patent metadata

Field	Value
Publication number	US-9912014-B2
Application number	US-201314012041-A
Country	US
Kind code	B2
Filing date	Aug 28, 2013
Priority date	Aug 28, 2012
Publication date	Mar 6, 2018
Grant date	Mar 6, 2018

Abstract

Embodiments of the invention generally relate to solid state battery structures, such as Li-ion batteries, methods of fabrication and tools for fabricating the batteries. One or more electrodes and the separator may each be cast using a green tape approach wherein a mixture of active material, conductive additive, polymer binder and/or solid electrolyte are molded or extruded in a roll to roll or segmented sheet/disk process to make green tape, green disks or green sheets. A method of fabricating a solid state battery may include: preparing and/or providing a green sheet of positive electrode material; preparing and/or providing a green sheet of separator material; laminating together the green sheet of positive electrode material and the green sheet of separator material to form a laminated green stack; and sintering the laminated green stack to form a sintered stack comprising a positive electrode and a separator.

First claim

What is claimed is:

1. A method of fabricating a solid state battery comprising:
providing a green sheet of positive electrode material;
providing a green sheet of separator material;
laminating together said green sheet of positive electrode material and said green sheet of separator material to form a laminated green stack;
sintering said laminated green stack to form a sintered stack, said sintered stack comprising a positive electrode and a separator;
laminating a negative electrode to said sintered stack; and
incorporating a layer of silicon or copper nitride at an interface between said negative electrode and said sintered stack;
wherein said negative electrode is a lithium metal electrode.

2. The method as in claim 1 , further comprising depositing a positive current collector on the surface of said positive electrode.

3. The method as in claim 1 , wherein said green sheet of positive electrode material is a continuous sheet, and wherein said green sheet of separator material is a continuous sheet.

4. The method as in claim 1 , wherein said green sheet of positive electrode material is attached to a positive current collector.

5. The method as in claim 1 , wherein said green sheet of positive electrode material comprises:
a Li(Mn,Co,Ni)O 2 material; and
a binding polymer.

6. The method as in claim 5 , wherein said green sheet of positive electrode material further comprises an electronic conductive additive.

7. The method as in claim 1 , wherein said green sheet of separator material comprises:
a pure ion conductor material; and
a polymer binder.

8. The method as in claim 7 , wherein said pure ion conductor material is Li 7-x La 3 Zr 2-x Ta x O 12 and x is greater than 0 and less than or equal to 1.

9. The method as in claim 1 , further comprising depositing a negative current collector on a surface of said negative electrode.

10. The method as in claim 1 , wherein said green sheet of positive electrode material is a segmented sheet, and wherein said green sheet of separator material is a segmented sheet.

11. The method as in claim 1 , wherein said solid state battery comprises lithium conducting solid electrolyte and LiNbO 3 coated LiCoO 2 active material.

12. The method as in claim 1 , wherein said green sheet of separator material comprises doped Li 7 La 3 Zr 2 O 12 garnet solid electrolyte.

13. The method as in claim 1 , wherein said green sheet of separator material comprises a sulphide based solid electrolyte.

14. The method as in claim 13 , wherein said sulphide based solid electrolyte is Li 10 GeP 2 S 12 .

15. The method as in claim 1 , wherein said green sheet of separator material comprises material selected from the group consisting of doped Li 7 La 3 Zr 2 O 12 garnet solid electrolyte and sulphide based solid electrolyte.

16. The method as in claim 1 , wherein said laminating said negative electrode to said sintered stack comprises passing said negative electrode and said sintered stack through pinch rollers.

17. The method as in claim 1 , wherein said layer of silicon or copper nitride is a layer of silicon.

18. The method as in claim 1 , wherein said layer of silicon or copper nitride is a layer of copper nitride.

19. A method of fabricating a solid state battery comprising:
providing a green sheet of positive electrode material;
providing a green sheet of separator material;
laminating together said green sheet of positive electrode material and said green sheet of separator material to form a laminated green stack;
sintering said laminated green stack to form a sintered stack, said sintered stack comprising a positive electrode and a separator;
laminating a negative electrode to said sintered stack; wherein said green sheet of separator material comprises a sulphide based solid electrolyte Li 10 GeP 2 S 12 , wherein said negative electrode is a lithium metal electrode; and
incorporating a layer of silicon or copper nitride at an interface between said negative electrode and said sintered stack.

Assignees

• Applied Materials Inc

Inventors

• Herle Subramanya P
• Gordon Ii Joseph G

Classifications

• H01M10/0562

  Solid materials · CPC title

• C04B2237/16

  Silicon interlayers · CPC title

• H01M10/14

  Assembling a group of electrodes or separators · CPC title

• H01M10/0413

  Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes · CPC title

• C04B35/52

  based on carbon, e.g. graphite · CPC title