JP5827565B2 - 統合された構造物内における多重電気化学電池およびエネルギー収集素子の製造および構造化方法 - Google Patents

統合された構造物内における多重電気化学電池およびエネルギー収集素子の製造および構造化方法 Download PDF

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JP5827565B2
JP5827565B2 JP2011535691A JP2011535691A JP5827565B2 JP 5827565 B2 JP5827565 B2 JP 5827565B2 JP 2011535691 A JP2011535691 A JP 2011535691A JP 2011535691 A JP2011535691 A JP 2011535691A JP 5827565 B2 JP5827565 B2 JP 5827565B2
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アルバーノ,ファビオ
ワン,カーウェイ
サストリ,アンマリー
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Description

関連出願の相互参照
本出願は、2008年11月7日に出願された発明の名称が「統合された構造物内における多重電気化学物質およびエネルギー収集素子の製造および構造化方法」という米国仮出願番号第61/112,707号に対する優先権を主張し、その内容が参照によって本出願に取り込まれる。
発明の要約
本発明によれば、エネルギー装置に関する技術が提供される。より詳細には、本発明の実施例は、統合された構造物を有する多成分エネルギー装置のデザイン、製造および構造化方法に関する。各個別構成要素は、電気化学電池、光電池、燃料電池、キャパシター、ウルトラキャパシター、熱電気素子、圧電素子、マイクロ電気機械タービン、またはエネルギー回収装置を含む。ここに記載された方法およびシステムは様々なエネルギーシステムに適用することができる。
本発明の実施例によれば、合体された電池および装置構造物を製造する方法が提供される。この方法は、互いに合体した2個以上の電気化学電池を提供することを含む。2個以上の電気化学電池は、関連した2個以上の電気化学物質を含む。また、本方法は、1個以上の装置が2個以上の電気化学電池と一体に形成され合体した電池および装置構造物を形成することを含む。
様々な利益が、従来技術を克服して本発明によって達成される。例えば、ここに記載された電気化学電池は様々な化学的性質を有しており、これにより、個別的な電池に比べてより広い電圧および電流の範囲を提供する。また、エネルギー回収素子は、エネルギーを集め、そのエネルギーを統合された構造物内の他の部品に補充するために使われる。本実施例によれば、1つ以上のこのような利益が達成されるはずである。これらおよび他の利益は本明細書により詳細に記載され、以下にてより具体的に記述する。
本発明の上述したものおよびその他の目的および特徴とそれを達成する方法は当業者には明らかなものであり、本発明は添付図面と共に以下の詳細な記載を参照すればよりよく分かるはずである。
図1は、合体したシリコン(Si)太陽電池および薄膜電池を含む、統合された構造物の概略断面図である。 図2は、他の化学物質を有する2つの合体した薄膜電池を含む、統合された構造物の概略断面図である。 図3は、合体した水素/酸素燃料電池と薄膜電池を含む、統合された構造物の概略断面図である。 図4は、合体したウルトラキャパシターと薄膜電池を含む、統合された構造物の概略断面図である。
具体的な実施例の詳細な記載
実施例1
シリコン(Si)太陽電池と薄膜電池を含む、統合された構造物とその製造方法
物理的気相蒸着(PVD)法を利用して電池部品を形成することにより、図1に示すようなシリコン(Si)太陽電池の後面に積層された電池が備えられる。P型シリコンを活用する太陽電池は従来のシリコンウェハー(Czochralski方法)を用いて構成される。リン(P)をウェハー内に拡散させてp−n接合を形成した後、物理的気相蒸着法を利用してシリコンウェハーのp+ドーピング領域(下部側)上にアルミニウム後面接点が形成される(図1の金属後面接点)。アルミニウム層は1−2μm厚さで成長される。
後面金属接点が形成された後、厚さが3−5μmであり、電気的に絶縁され、熱的伝導性を有する窒化アルミニウム(AlN)の分離層がPVD法を利用してアルミニウム層上に製造される。この層は、2つの素子から熱を除去し、その熱をヒートシンクに伝達する機能を有する。
冷却素子が完成された後、アルミニウム電流コレクタ層(厚さ1−3μm)、リチウムマンガン酸化物(LiMn)カソード層(厚さ3−5μm)、リン酸リチウムオキシナイトライド(LiPON)セラミック電解質層(厚さ1−3μm)、リチウム(Li)金属アノード層(厚さ3−5μm)、および銅(Cu)電流コレクタ層(厚さ1−3μm)のような電池部品が物理的気相蒸着法によって等角的に順次積層される。
実施例2
相異なる化学物質を有する2つの薄膜電池を含む、統合された構造物とその製造方法
図2に示すように物理的気相蒸着法を利用し、相異なる電気化物質を有する2つの積層された電池が製造される。
カソード電流コレクタとして用いられるアルミニウム(Al)金属膜上に、リチウム鉄リン酸塩(LiFePO)カソード層(厚さ3−5μm)、リン酸リチウムオキシナイトライド(LiPON)セラミック電解質層(厚さ1−3μm)、リチウム(Li)金属アノード層(厚さ3−5μm)、および銅(Cu)電流コレクタ層(厚さ1−3μm)のような第1電池構成要素がPVD法によって各々蒸着される。
銅金属電流コレクタが形成された後、厚さが3−5μmであり、電気的に絶縁され、熱的伝導性を有する窒化アルミニウム(AlN)分離層がPVD法を利用して銅層上に製造される。この層は、2つの素子から熱を除去し、その熱をヒートシンクに伝達する機能を有する。
冷却素子が完成された後、アルミニウム電流コレクタ層(厚さ1−3μm)、リチウムマンガン酸化物(LiMn)カソード層(厚さ3−5μm)、リン酸リチウムオキシナイトライド(LiPON)セラミック電解質層(厚さ1−3μm)、リチウム(Li)金属アノード層(厚さ3−5μm)、および銅(Cu)電流コレクタ層(厚さ1−3μm)のような2次電池部品がPVD法によって等角的に順次蒸着される。
実施例3
燃料電池および薄膜電池を含む、統合された構造物とその製造方法
物理的気相蒸着法(PVD法)を利用して電池部品を形成することにより、図3に示すようなプロトン交換膜(PEM)燃料電池の後面に積層された電池を準備する。Nafion(登録商標)のようなペルフルオロスルホン酸塩アイオノマー電解液を採用する、高いプロトン伝導率を有するプロトン交換膜を活用するPEM燃料電池が、電極用膜および湿式スラリーを製造する従来のゾル−ゲル方法を利用して構成される。
燃料電池を組み立てた後、厚さが3−5μmであり、電気的に絶縁され、熱的伝導性を有する窒化アルミニウム(AlN)分離層がPVD法を利用して燃料電池電流コレクタ上に製造される。この層は、2つの素子から熱を除去し、その熱をヒートシンクに伝達する機能を有する。
冷却素子が完成された後、アルミニウム電流コレクタ層(厚さ1−3μm)、リチウムマンガン酸化物(LiMn)カソード層(厚さ3−5μm)、リン酸リチウムオキシナイトライド(LiPON)セラミック電解質層(厚さ1−3μm)、リチウム(Li)金属アノード層(厚さ3−5μm)、および銅(Cu)電流コレクタ層(厚さ1−3μm)のような電池部品が物理的気相蒸着法によって等角的に順次積層される。
実施例4
ウルトラキャパシターと薄膜電池を含む、統合された構造物とその製造方法
PVD法を利用して電池部品を形成することにより、図3に示すような、ウルトラキャパシターと知られた電気化学的二重層キャパシター(EDLC)の後面に積層された電池を準備する。このようなハイブリッドシステムにおいて、EDLCはシステム内において高パワー容量を可能にし、電池は高いエネルギー密度を提供する。
EDLCは、高表面積炭素(活性炭)、電気活性高分子、遷移金属酸化物および窒化物を含む活性物質を組み合わせたエネルギー貯蔵装置の一種である。分離材料としては、改良された誘電体、従来および改良された高分子電解質、イオン伝導物質を含む。電極の配列は対称であってもよく、反対称であってもよい。図4において、素子電極に対しては反対称の電極配列が利用されている。キャパシターの電極は、キャパシタンスが最大700F/gであるゾル−ゲル方法によって製造された金属酸化物(例えば、ルテニウムオキシド水和物、RuO・0.5HO)のような高いキャパシタンスを有する酸化還元活性物質である活性炭のような高表面積物質によって形成される。反対称電極と相異なるアノードおよびカソード物質を用いることは、使用電圧をさらに高くし、このような素子のエネルギー貯蔵能力を改善させる。
ウルトラキャパシターを組み立てた後、厚さが3−5μmであり、電気的に絶縁され、熱的伝導性を有する窒化アルミニウム(AlN)分離層がPVD法を利用して誘電材料層上に製造される。この層は、2つの素子から熱を除去し、その熱をヒートシンクに伝達する機能を有する。
冷却素子が完成された後、アルミニウム電流コレクタ層(厚さ1−3μm)、リチウムマンガン酸化物(LiMn)カソード層(厚さ3−5μm)、リン酸リチウムオキシナイトライド(LiPON)セラミック電解質層(厚さ1−3μm)、リチウム(Li)金属アノード層(厚さ3−5μm)、および銅(Cu)電流コレクタ層(厚さ1−3μm)のような電池部品がPVD法によって等角的に順次積層される。
ここに記載された実施例および実施形態は例示のみを目的とするものであり、それらを踏まえたさまざまな応用または変形が当業者に提案され、それらが本出願の精神および範囲の範疇に含まれ、添付の請求項の範囲内であることは明白である。

Claims (3)

  1. 統合された装置を製造する方法であって、
    2個以上の積層された電気化学セルを準備するステップ、
    を備え、
    前記2個以上の積層された電気化学セルは、2つ以上の異なる電気化学物質を有し、
    前記電気化学セルを準備するステップは、
    ゾルーゲル法を用いて、燃料電池を製造するステップと、
    前記燃料電池の電流コレクタ層上に物理的気相蒸着処理により、分離層を形成するステップと、
    前記分離層を形成後、当該分離層上に、物理的気相蒸着処理により連続的に、他の電気化学セルの電流コレクタ層、カソード層、電解質層、アノード層および電流コレクタ層を順次堆積するステップを備え
    ることを特徴とする方法。
  2. 前記2個以上の電気化学セルは、直列および/または並列に積層し構成されることを特徴とする、請求項1記載の方法
  3. 前記2つ以上の異なる電気化学物質は、リチウム鉄リン酸塩(LiFePO)、リン酸リチウムオキシナイトライド(LiPON)、リチウム(Li)、銅(Cu)アルミニウム、リチウムマンガン酸化物(LiMn)から選択されることを特徴とする、請求項1又は2に記載の方法。
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US20140050857A1 (en) 2014-02-20
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KR20110091757A (ko) 2011-08-12
CN105206791A (zh) 2015-12-30

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