CN102210023B - 一体式结构中的多个电化学和聚能组件的制造方法和结构 - Google Patents

一体式结构中的多个电化学和聚能组件的制造方法和结构 Download PDF

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CN102210023B
CN102210023B CN200980144551.2A CN200980144551A CN102210023B CN 102210023 B CN102210023 B CN 102210023B CN 200980144551 A CN200980144551 A CN 200980144551A CN 102210023 B CN102210023 B CN 102210023B
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electrochemical cells
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CN102210023A (zh
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法比奥·阿尔巴诺
汪家伟
安玛丽·沙斯特里
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Sakti3 Inc
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Abstract

本发明的提供具有一体式结构的多组件能源装置的设计、制造和构造方法，其中，单个组件可选自包括电化学电池、光电池、燃料电池、电容器、超级电容器、热电元件、压电元件、微电机涡轮和能量收集器的列表中。所述组件被组织成一个结构，以达到单个组件不能单独达到的能量密度、功率密度、电压范围和寿命范围，也就是说，所述单个组件互补。所述单个组件形成混合结构，其中，元件之间互相电气、化学和热传导。与单个电化学电池相比，所述电化学电池表现出多种化学特性以适应更宽的电压和电流范围。采用能量收集元件来收集能量并将所收集的能量补充到一体式结构中的其它组件。

Description

一体式结构中的多个电化学和聚能组件的制造方法和结构
相关申请的交叉引用
本申请要求2008年11月7日提交的名称为“一体式结构中的多个电化学和聚能组件的制造方法和结构”的美国临时专利申请No.61/112,707的优先权，其全部内容通过引用合并于此以用于各种用途。
技术领域
根据本发明，提供涉及能源装置的技术。更具体地，本发明的实施例涉及具有一体式结构的多组件能源装置的设计、制造和构造方法。单个组件可包括电化学电池、光电池、燃料电池、电容器、超级电容器、热电元件、压电元件、微电机涡轮或能量收集器（energy scavenger）。本文所描述的方法和系统也可以应用于各种能源系统。
背景技术
目前使用的单个电化学电池仅能表现出单个化学特性，从而适应的电压和电流范围较窄。此外，由于电池之间相互独立，从而采用能量收集元件收集的能量不能补充到其它组件。
发明内容
根据本发明的实施例，提供一体化电池组和器件结构的制造方法。所述方法包括提供互相结合为一体的两个或多个电化学电池。所述两个或多个电化学电池包括相关的两种或多种电化学物质。所述方法还包括形成与所述两个或多个电化学电池一体的一个或多个器件，以形成一体化电池组和器件结构。
利用本发明可以获得超过常规技术的许多优点。例如，与单个电池相比，本文描述的电化学电池表现出多种化学特性以适应更宽的电压和电流范围。此外，采用能量收集元件来收集能量并将所收集的能量补充到一体式结构中的其它组件。依据所述实施例，可以获得这些优点中的一个或多个。将在本说明书中，尤其是下文中，更详细地描述这些和其它优点。
通过参照结合附图进行说明的下述详细描述，本发明的这些和其它目的和特点以及获得这些和其它目的和特点的方法对于本领域技术人员来说将变得显而易见，并且可以最佳地理解本发明本身。
附图说明
图1是包括一体化硅（Si）太阳能电池和薄膜电池组的一体式结构的简化剖视图；
图2是包括化学特性不同的两个一体化薄膜电池组的一体式结构的简化剖视图；
图3是包括一体化氢/氧燃料电池和薄膜电池组的一体式结构的简化剖视图；
图4是包括一体化超级电容器和薄膜电池组的一体式结构的简化剖视图。
具体实施方式
实例1
包括硅（Si）太阳能电池和薄膜电池组的一体式结构及其制造方法
通过利用物理气相沉积形成电池器件可以实现如图1所示的在硅（Si）太阳能电池的后表面上制备堆叠电池。使用传统的Si晶片构造利用p型硅的太阳能电池（提拉法）。在通过将磷（P）扩散到晶片中而形成p-n结之后，利用物理气相沉积在硅晶片的p+掺杂区（下侧）形成铝（Al）背接触（图1中的金属背接触）。铝层生长到l-2μm的厚度。
在形成背金属接触后，利用PVD（physical vapor deposition，物理气相沉积）在铝层上制作厚度为3-5μm的用于电绝缘和热传导的氮化铝（AlN）隔离层。所述隔离层用于从两个元件移除热量并将热量传递到散热器。
在元件冷却完毕之后，通过物理气相沉积（PVD）过程顺序地和以保形方式沉积电池组组件，分别为：铝（Al）集电极（current collector）层（l-3μm厚）、锂锰氧化物（LiMn2O4）阴极层（3-5μm厚）、锂磷氮氧（LIPON）陶瓷电解质层（1-3μm厚）、锂（Li）金属阳极层（3-5μm厚）以及铜（Cu）集电极层（1-3μm厚）。
实例2
包括化学特性不同的两个薄膜电池组的一体式结构及其制造方法
如图2所示，利用物理气相沉积使电化学物质不同的两个堆叠电池形成在彼此上。
利用PVD过程在用作阴极集电极的铝（Al）金属薄膜上沉积第一电池组组件，分别为：磷酸锂铁（LiFePO4）阴极层（3-5μm厚）、锂磷氮氧（LIPON）陶瓷电解质层（1-3μm厚）、锂（Li）金属阳极层（3-5μm厚）以及铜（Cu）集电极层（1-3μm厚）。
在形成铜（Cu）金属集电极后，利用PVD在铜层上制作厚度为3-5μm的用于电绝缘和热传导的氮化铝（AlN）隔离层。所述隔离层用于从两个元件移除热量并将热量传送到散热器。
在元件冷却完毕之后，通过PVD过程顺序地和以保形方式沉积第二电池组组件，分别为：铝（Al）集电极层（l-3μm厚）、锂锰氧化物（LiMn2O4）阴极层（3-5μm厚）、锂磷氮氧（LIPON）陶瓷电解质层（1-3μm厚）、锂（Li）金属阳极层（3-5μm厚）以及铜（Cu）集电极层（1-3μm厚）。
实例3
包括燃料电池和薄膜电池组的一体式结构及其制造方法
通过利用物理气相沉积（PVD）形成电池组件可以实现如图3所示的在质子交换膜（PEM，proton-exchange membrane）燃料电池的后表面上制备堆叠电池。使用用于制作电极的所述膜和湿浆体（wet slurry）的传统溶胶凝胶法构造采用具有高质子传导性的质子交换膜并且利用诸如的全氟磺酸盐（perfluorosulfonate）离聚物电解质的PEM燃料电池。
在装配燃料电池后，利用PVD在燃料电池集电极上制作厚度为3-5μm的用于电绝缘和热传导的氮化铝（AlN）隔离层。所述隔离层用于从两个元件移除热量并将热量传送到散热器。
在元件冷却完毕之后，通过PVD过程顺序地和以保形方式沉积电池组组件，分别为：铝（Al）集电极层（l-3μm厚）、锂锰氧化物（LiMn2O4）阴极层（3-5μm厚）、锂磷氮氧（LIPON）陶瓷电解质层（1-3μm厚）、锂（Li）金属阳极层（3-5μm厚）以及铜（Cu）集电极层（1-3μm厚）。
实例4
包括超级电容器和薄膜电池组的一体式结构及其制造方法
通过利用PVD形成电池组件可以实现如图3所示的在电化学双层电容器（electrochemical double layer capacitor，EDLC）（也被称作超级电容器）的后表面上制备堆叠电池。在这种混合系统中，电池组提供高能量密度，同时EDLC使系统中具有高功率容量。
EDLC描述了一类能量存储器件，所述能量存储器件含有包括表面积大的炭（活性炭）、电活性聚合物、过渡金属氧化物和氮化物的活性材料。隔离材料包括高性能电介质、常规的高性能聚合物电解质和离子导电材料。可以对称或不对称地布置电极。在图4中，示出了器件电极的不对称的电极布置。可以通过诸如活性炭之类的表面积大的材料、诸如金属氧化物（例如，含水钌氧化物，RuO2·0.5H2O）之类的高电容的氧化还原性材料形成电容器的电极，所述金属氧化物通过溶胶凝胶法来制备且具有高达700F/g的电容量。使用引起工作电压增高的不对称电极以及不同的阳极和阴极材料可以提高此元件的能量存储量。
在装配超级电容器后，利用PVD在电介质材料层上制作厚度为3-5μm的用于电绝缘和热传导的氮化铝（AlN）隔离层。所述隔离层用于从两个元件移除热量并将热量传送到散热器。
在元件冷却完毕之后，通过PVD过程顺序地和以保形方式沉积电池组组件，分别为：铝（Al）集电极层（l-3μm厚）、锂锰氧化物（LiMn2O4）阴极层（3-5μm厚）、锂磷氮氧（LIPON）陶瓷电解质层（1-3μm厚）、锂（Li）金属阳极层（3-5μm厚）以及铜（Cu）集电极层（1-3μm厚）。
应该理解，本文所描述的实例和实施例仅为了说明的目的，本领域技术人员可以提出依据本发明的各种改进或变型，并且这些改进或变型包括在本申请的精神和范围以及所附权利要求的范围内。

Claims (19)

1.一种一体化电池组和器件结构的制造方法，所述方法包括：
提供互相结合为一体的至少两个堆叠的电化学电池，所述至少两个堆叠的电化学电池包括相关的至少两种电化学物质；形成与至少两个电化学电池一体的一个或多个器件，以形成所述一体化电池组和器件结构；以及
设置在所述至少两个堆叠的电化学电池之间的被构造为用于热传递的隔离区；
其中，所述至少两个堆叠的电化学电池以及所述一个或多个器件利用一种或多种技术结合为一体式结构，所述一种或多种技术选自物理气相沉积(PVD)、化学气相沉积(CVD)、电镀、原子层沉积(ALD)、激光直写(DLW)、纳米压印、离子注入、激光烧蚀、喷射沉积、喷雾热分解、喷雾涂布、等离子体喷涂、溶胶/凝胶浸渍纺丝。
2.如权利要求1所述的方法，其中，所述至少两个电化学电池被构造为串联地堆叠。
3.如权利要求1所述的方法，其中，被构造为用于热传递的所述隔离区至少由金刚石、氧化铝、氮化硼、氮化铝或碳化硅形成。
4.如权利要求1所述的方法，其中，所述器件包括一个或多个燃料电池。
5.如权利要求1所述的方法，其中，所述器件包括一个或多个光电池。
6.如权利要求1所述的方法，其中，所述器件包括一个或多个电容器。
7.如权利要求1所述的方法，其中，所述器件包括一个或多个超级电容器。
8.如权利要求1所述的方法，其中，所述器件包括一个或多个压电元件。
9.如权利要求1所述的方法，其中，所述器件包括一个或多个热电元件。
10.如权利要求1所述的方法，其中，所述器件包括一个或多个微电机涡轮。
11.如权利要求1所述的方法，其中，所述器件包括单元的混合组合，所述单元选自由燃料电池、光电池、电容器、压电元件、热电元件和微电机涡轮所组成的组。
12.如权利要求1所述的方法，进一步包括与所述一个或多个器件逻辑联系和通信的包含数据总线的监测装置，以及中央计算和处理单元(CPU)，所述中央计算和处理单元控制一个或多个单独的元件。
13.如权利要求12所述的方法，其中，所述监测装置被构造为检测温度T。
14.如权利要求12所述的方法，其中，所述监测装置被构造为检测一个或多个组件中的应力。
15.如权利要求12所述的方法，其中，所述监测装置被构造为检测由所述至少两个电化学电池或者所述一个或多个器件至少之一的工作产物所产生的气体和气体反应。
16.如权利要求12所述的方法，其中，所述监测装置被构造为检测锂成分和穿过阳极和阴极隔离层的转变。
17.如权利要求1所述的方法，进一步包括使用一个或多个监测装置以保持所述至少两个电化学电池或者所述一个或多个器件的安全工作。
18.如权利要求1所述的方法，进一步包括如果温度升高为超过设置的阈值，则启动包括液态冷却剂或液化气体的冷却系统，与散热器热接触的所述冷却系统被设计为利用一个或多个传导路径移除热量。
19.如权利要求1所述的方法，其中，所述至少两个电化学电池被构造为利用混合原理来优化器件架构、排列、能量和功率密度以及可充电性和寿命。
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