CN101485031A - 制造薄膜电化学能源的方法和装置 - Google Patents

制造薄膜电化学能源的方法和装置 Download PDF

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CN101485031A
CN101485031A CNA2007800254059A CN200780025405A CN101485031A CN 101485031 A CN101485031 A CN 101485031A CN A2007800254059 A CNA2007800254059 A CN A2007800254059A CN 200780025405 A CN200780025405 A CN 200780025405A CN 101485031 A CN101485031 A CN 101485031A
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R·A·H·尼森
P·H·L·诺坦
F·鲁泽布姆
F·A·C·M·斯库夫斯
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Abstract

本发明涉及一种制造薄膜电化学能源的方法。本发明还涉及一种薄膜电化学能源。本发明还涉及一种包括这种薄膜电化学能源的电气装置。本发明允许能够更快更高效地制造薄膜电池和包含这种电池的装置。

Description

制造薄膜电化学能源的方法和装置
技术领域
本发明涉及一种制造薄膜电化学能源的方法。本发明还涉及一种薄膜电化学能源。本发明还涉及一种包括这种薄膜电化学能源的电气装置。
背景技术
根据本领域的现有技术，制造薄膜电池包括如下步骤：将第一电极层沉积在衬底上(通常不导电)，将电解质层沉积在第一电极上，并将第二电极层沉积在电解质层上，其中第一电极层与第二电极层中之一是阳极材料而另一电极是阴极材料。这种层堆栈(衬底-阳极-电解质-阴极或者衬底-阴极-电解质-阳极)可以重复，以得到一系列电池的堆栈。通常，沉积方法包括化学和物理气相沉积技术以及sol-gel技术。各层沉积之后，通过施加一段时间的电流使得电池充电，直到达到预先确定的电池充电电平。
典型例子是锂离子电池，其由材料层组成，其中典型的阳极材料是金属锂(Li)，而阴极材料是诸如LiCoO2的材料。沉积之后，电池经历静电充电过程，在该过程中电池被充电以便使用。对电池充电是花费时间的过程。电池堆栈中的缺陷在充电之后或者充电过程中可能变得明显。没有所需规范的电池通常不得不被丢弃。
发明内容
本发明的目标是克服上述缺点。
本发明的目标通过一种制造薄膜电化学能源的方法来实现，该方法包括如下步骤：将第一电极层沉积在衬底上，将电解质层沉积在第一电极上，并将第二电极层沉积在电解质层上，其中第一电极层与第二电极层中之一是阳极材料而另一电极是阴极材料，其特征在于，阳极材料和阴极材料被沉积为充电状态下的材料，形成充电的电池堆栈。由于得到的薄膜电池已经被充电，所以省略了对电池充电的处理步骤，因此该方法比现有方法快。除了构成功能电池的这些基本层(阳极、电解质、阴极)，其它功能层也可被沉积在这些层之间。该方法的产品优选地提供了被完全充电的电池，但也可以是部分充电的，以便达到根据本发明的优点。电池的层堆栈序列(衬底-阳极-电解质-阴极或者衬底-阴极-电解质-阳极)可以重复，以得到电池组堆栈。电池可以是二维或三维的层系统。优选地，电化学能源是可再充电的电池系统。
优选地，在沉积了至少一个电极层之后，所形成层或层堆栈的至少一个电特征被测量。电特征通常包括电势和电阻。这样，沉积的层或层堆栈中的缺陷可以在诸如应用附加层的任何进一步的处理步骤执行之前而被检测。如果该缺陷被确定为大于预先确定的阈值，则电池可以在任何进一步的处理步骤执行之前而被丢弃。这样，可以制造高质量的产品，以及提高工作流程和材料使用的效率。根据本领域现有技术，对于未充电的电极材料，需要外部电源来检测层的缺陷，这样复杂得多。
优选地，本方法被应用在装置制造中，其中该装置的功能在制造过程中利用来自装配好的薄膜电化学能源的能量而被检测。这样，检查装置或装置各部分的功能并一步一步地监视生产相对容易。该方法使得可以及时校正装置缺陷，和/或从生产线上提前拆除有缺陷的样本。这样可节约时间和材料，并获得更加可靠的装置。特别是诸如微处理器的昂贵部分可被节省下来用在正确工作的装置，而不是用在制造过程中被注意到缺陷的装置中。
在优选实施例中，该装置从包括如下内容的组中选择：照明装置、可移植装置、助听器、传感器装置和DC/DC转换器。在这些装置中，可靠性是特别重要的。
如果薄膜电化学能源是锂离子电池则是有益的，其中阳极被沉积为富锂材料，而阴极被沉积为缺锂材料。锂离子电池具有相对较高的能量密度。对锂离子可重复充电电池充电会花费大量的时间，通过使用根据本发明的方法可节省这一时间。富锂阳极材料或缺锂阴极材料的沉积可通过本领域公知的沉积方法来实现。富锂阳极材料例如可以是包含预先确定的锂浓度的金属锂(Li)、锂铝合金(Li-Al)或者锂锡合金(Li-Sn)。缺锂阴极材料例如可以是Li0.1MnO2、LiXNiO2、LixV2O5，其中出现非常低水平的锂离子，通常x＝0.1或更低。电解质层通常包括固体电解质，该固体电解质中包含移动锂离子。
优选地，富锂阳极材料是LixSi，其中x从1到4.4。各种沉积方法适用于获得这种层，然而，最优选的方法是在超高真空中蒸发预先确定数量的金属锂和元素硅(电子束沉积)。
如果缺锂阴极材料是LiyCoO2，其中y从0.5到0.6，则是优选的。这种材料也可方便地用各种方法沉积。优选方法是溅射具有想要成分的LiyCoO2粉末，优选地使用DC或RF磁控溅射。
用LixSi作为富锂阳极材料和用LiyCoO2作为缺锂阴极材料的组合是特别有益的。
在另一优选实施例中，薄膜电化学能源是金属氢化物电池，其中阳极被沉积为金属氢化物，而阴极被沉积为金属氢氧化物。电解质通常包括能够将氢作为氢化物阴离子或质子传送的固体电解质。各种阳极电极材料适用于例如LaNi5或者MgNi2。渗氢(hydrogen-charged)形式的这些材料易于在层的合成之后通过氢化作用获得，或者在氢-氩(H2/Ar)气氛中通过反应溅射法获得。
如果金属氢化物是镁钛氢化物则是优选的。镁钛氢化物(MgTiHx)利用例如高真空下金属镁和钛的蒸发并继之以氢化作用，或者通过在氢-氩(H2/Ar)气氛中进行反应溅射法而方便地沉积。
优选地，金属氢氧化物是氢氧化镍。氢氧化镍(Ni(OOH))例如通过sol-gel沉积方法而方便地沉积。
本发明还提供通过根据本发明的方法获得的薄膜电化学能源。这种电池具有便于在装配时使用的优点。通过层质量控制获得的电池，如上所述的电特征的槽确定，具有比公知电池改善的可靠性。并且，由于省略了没有用的对缺陷部分的进一步处理，根据本发明的电池成本低于公知电池。
本发明进一步提供包括根据本发明的薄膜电化学能源的电气装置。由于改善的电池质量以及利用预先充电的电池能量在制造过程中监视装置的装配，这种装置具有胜于已知装置的可靠性。
这些优点对于其中在装置中集成有薄膜电化学能源的装置来说是最为突出的。
现在将通过下面的非限制例子来进一步阐释本发明。
附图说明
图1a和1b示出了根据本发明准备的薄膜电池。
具体实施方式
图1a示出了二维电池，由阳极层2、电解质层3和阴极层4组成。该电池1通过首先将阴极材料4(Li0.5CoO2)沉积在衬底5上，然后沉积电解质层3和由Li4Si构成的阳极层(2)来制备。得到的电池在没有充电步骤的情况下被准备好使用。在现有技术中，锂离子应当首先被电化学地从包含阴极材料的锂传送到阳极(Si)层，得到Li4Si阳极。根据本发明在所述方法中省略了该额外的步骤，导致时间效率提高。在堆栈顶部，采用集电器6。阳极层2和阴极层4的相对位置是任意的，并且可以颠倒过来而不会对生产过程造成影响。堆栈层的电特征可以用已知技术来测量。
图1b与图1a相同，利用相对应的附图标记，但不同的是堆栈1’包括几个串联的如图1a所示的重复单元。生产过程中，可通过测量诸如电阻的电特征来检查堆栈1’的缺陷。还可以当仅仅部分堆栈层被沉积时进行电特征的测量，例如在每个电池单元沉积之后。不需要外部电源用于这些检查，因为电池本身能够提供必须的能量。如果电池堆栈不满足预先确定的需要，则可从生产周期取出，以便节约可能无用的进一步的处理步骤。这样，相对于本领域公知的方法来说节省了时间，在电池堆栈中的任何缺陷变得明显之前，全部处理以及耗费时间的充电步骤都是必需的。
在另一应用中，包含充电阳极和阴极材料的完全电池在制造过程中可被立即用于检测装置或装置组件。这样，设备中的缺陷可被及时检测，并且缺陷被修补或有缺陷的部分被丢弃。这种方法在其中集成有电池的装置中特别有用。
对本领域技术人员来说，所给出的本发明的很多变化和应用是可以实现的。

Claims (13)

1、一种制造薄膜电化学能源的方法，包括如下步骤：
-将第一电极层(4，4’)沉积在衬底上(5)上，
-将电解质层(3，3’)沉积在第一电极(4，4’)上，和
-将第二电极层(2，2’)沉积在电解质层(3，3’)上，
其中第一电极层(4，4’)与第二电极层(2，2’)中之一是阳极材料而另一电极是阴极材料，其特征在于，阳极材料和阴极材料被沉积为充电状态的材料，形成充电的电池堆栈。
2、根据权利要求1的方法，其特征在于，在沉积至少一个电极层(2，2’，4，4’)之后，所形成的层或层堆栈(1，1’)的至少一个电特征被测量。
3、根据权利要求1或2的方法，其特征在于，该方法被应用在装置制造中，其中装置的功能在制造过程中利用来自装配好的薄膜电化学能源的能量而被检测。
4、根据权利要求3的方法，其特征在于，该装置从包括如下内容的组中选择：照明装置、可移植装置、助听器、传感器装置和DC/DC转换器。
5、根据前述任意一项权利要求所述的方法，其特征在于，薄膜电化学能源是锂离子电池，其中阳极被沉积为富锂阳极材料，而阴极被沉积为缺锂阴极材料。
6、根据权利要求5的方法，其特征在于，富锂材料是LiXSi，其中x从1到4.4。
7、根据权利要求5或6的方法，其特征在于，缺锂阴极材料是LiyCoO2，其中y从0.5到0.6。
8、根据前述权利要求1-4中任意一项的方法，其特征在于，薄膜电化学能源是金属氢化物电池，其中阳极被沉积为金属氢化物，而阴极被沉积为金属氢氧化物。
9、根据权利要求8的方法，其特征在于，金属氢化物是镁钛氢化物。
10、根据权利要求8或9的方法，其特征在于，金属氢氧化物是氢氧化镍。
11、可通过根据前述任意一项权利要求的方法获得的薄膜电化学能源。
12、包括根据权利要求11的薄膜电化学能源的电气装置。
13、根据权利要求12的电气装置，其特征在于，薄膜电化学能源被集成在该装置中。
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