Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M6/00—Primary cells; Manufacture thereof
  • H01M6/40—Printed batteries, e.g. thin film batteries
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/04—Construction or manufacture in general
  • H01M10/0436—Small-sized flat cells or batteries for portable equipment
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/058—Construction or manufacture
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/04—Processes of manufacture in general
  • H01M4/0402—Methods of deposition of the material
  • H01M4/0421—Methods of deposition of the material involving vapour deposition
  • H01M4/0428—Chemical vapour deposition
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/052—Li-accumulators
  • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
  • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/49108—Electric battery cell making
  • Y10T29/49115—Electric battery cell making including coating or impregnating

Definitions

• the present invention relates generally to electrical energy sources, and particularly to three-dimensional (3-D) microbatteries. BACKGROUND OF THE INVENTION
• MEC thin-film micro-electrochemical energy storage cells
• DLC double-layer capacitors
• the energy storage cells comprise two thin layer electrodes, an intermediate thin layer of a solid electrolyte and an optional fourth thin current collector layer.
• the layers are deposited in sequence on a surface of a substrate.
• the substrate comprises multiple through cavities of arbitrary shape, with high aspect ratio, which increase the total electrode area per volume ratio.
• the micro-containers are filled with appropriate anode and cathode materials and used as the electrodes of the microbattery.
• the anodes and cathodes are arranged in an interlaced pattern and are separated by walls of substrate material.
• the walls of the substrate that separate the micro-containers are processed to enhance their ion- conductivity and electrical insulation.
• Embodiments of the present invention provide improved miniature three-dimensional (3-D) electrical energy storage devices, such as 3-D microbatteries, and methods for fabricating such cells.
• the energy cell is fabricated in a substrate having multiple miniature cavities formed therein.
• the cathode, separator layer and anode are formed in the 3-D structure.
• the different layers are inserted into the interior of the cavities.
• the electrolyte separator layer fills the interior of the cavities and extends over the outer surface of the substrate.
• the second electrode is attached to the electrolyte separator layer on the surface of the substrate.
• an electrical energy storage device including: a substrate having an outer surface and having a plurality of cavities communicating with the outer surface, the cavities having interior cavity surfaces; a first electrode layer deposited at least over the interior cavity surfaces; an electrolyte separator layer formed over the first electrode layer so as to fill the cavities and to extend over the outer surface of the planar substrate; and a second electrode layer formed over the electrolyte separator layer on the outer surface of the planar substrate.
• the substrate has at least one of a planar and a spherical shape.
• the substrate may include at least one of a perforated plate and a microchannel plate (MCP).
• MCP microchannel plate
• the substrate has two opposite outer surfaces, the cavities include through cavities communicating with the two outer surfaces, the electrolyte separator layer extends over the two outer surfaces, and the second electrode layer is formed over the electrolyte separator layer on the two opposite outer surfaces.
• the substrate may include at least one of a semiconductor, a glass, a plastic, a metal, an alloy, carbon and a composite material, hi yet another embodiment, a ratio of a height of the cavities divided by a width of the cavities is greater than unity.
• the device further includes a first hollow current collector layer coating at least part of the substrate and deposited between the interior cavity surfaces of the substrate and the first electrode layer. Additionally or alternatively, the device may include a second current collector layer formed over the second electrode layer.
• one of the first and second electrode layers includes a cathode of the device, and the other of the first and second electrode layer includes an anode of the device.
• the cathode includes at least one of molybdenum oxysulfide
• the cathode includes a composite cathode having a polymer added thereto.
• the anode includes at least one of graphite, an alkali metal and an alkali metal alloy.
• the electrolyte separator layer includes at least one of a hybrid polymer electrolyte (HPE) membrane, a gel electrolyte, a solid ceramic electrolyte and a solid polymer electrolyte.
• HPE hybrid polymer electrolyte
• a method for constructing an electrical energy storage device including: providing a substrate having an outer surface and having a plurality of cavities communicating with the outer surface, the cavities having interior cavity surfaces; depositing a first electrode layer at least over the interior cavity surfaces; forming an electrolyte separator layer over the first electrode layer so as to fill the cavities and to extend over the outer surface of the planar substrate; and forming a second electrode layer over the electrolyte separator layer on the outer surface of the planar substrate.
• depositing the first electrode layer includes applying at last one of an electrochemical deposition process, an electroless deposition process and a chemical vapor deposition process. Additionally or alternatively, forming the electrolyte separator layer includes inserting the electrolyte layer into the cavities using at least one of a spin-coating process, a vacuum-assisted pulling process, a pasting process, a pressure-filling process and a casting process.
• Fig. 1 is a pictorial, schematic illustration of a perforated substrate, in accordance with an embodiment of the present invention
• Fig. 2 is a pictorial, schematic illustration of a microbattery, in accordance with an embodiment of the present invention
• Fig. 3 is a schematic top view cross-section of a microbattery, in accordance with an embodiment of the present invention
• Fig. 4 is a flow chart that schematically illustrates a method for fabricating a microbattery, in accordance with an embodiment of the present invention.
• Figs. 5 and 6 are graphs that show capacities of microbatteries, in accordance with embodiments of the present invention.
• Fig. 1 is a pictorial, schematic illustration of a perforated substrate 20 used a base for constructing a microbattery 10, in accordance with an embodiment of the present invention.
• substrate 20 comprises a planar structure having two opposite faces, although substrates having other shapes and forms, such as spherical substrates, can also be used.
• Multiple through cavities 22 perforate substrate 20, penetrating the entire thickness of the substrate from one face to the other.
• substrate 20 comprises a wafer or other plate in which cavities 22 are formed using a suitable electrochemical etching or lithography process. Exemplary methods for producing cavities are described in PCT Patent Application PCT/IL2005/000414 cited above, which is assigned to the assignee of the present patent application.
• the substrate material may comprise a semiconductor such as silicon, a plastic, a metal, an alloy, a carbon, a composite material or any other suitable material.
• substrate 20 may comprise a microchannel plate (MCP) structure, i.e., a two-dimensional array of very-small diameter tubes, which are fused together and sliced to form a thin plate.
• MCPs are most commonly made of glass, but can also be made of other materials, such as carbon fibers. MCPs are commercially available from a number of different sources, such as Del Mar Ventures (San Diego, California) and Burle Electro-Optics, Inc. (Sturbridge, Massachusetts). Methods for producing MCPs are described, for example, in U.S. Patents 6,300,709, 6,260,388 and 6,270,714, whose disclosures are incorporated herein by reference.
• substrate 20 may comprise a wafer in which cavities 22 are formed using a suitable electrochemical etching or lithography process. Exemplary methods for producing cavities are described in PCT Patent Application PCT/IL2005/000414 cited above, which is assigned to the assignee of the present patent application.
• the thickness of substrate 20 (and thus the height of cavities 22) is preferably in the range of 100-800 microns, although the methods described below can be used to fabricate microbatteries in substrates of any thickness.
• the characteristic width or diameter of the cavities is typically on the order of several tens of microns.
• the cavities have an aspect ratio (i.e., a height-to-width ratio) greater than one.
• the cavities are separated by substrate walls having a thickness that may typically vary from 1 micron and up to several tens of microns.
• the total number of micro-containers in a typical microbattery can vary from several hundreds to several tens of thousands, depending on the cavity diameter, the wall thickness and the electrical specifications of the battery.
• the cavities have a high aspect ratio, i.e., their height is significantly larger than their diameter.
• the examples below show cylindrical cavities having round cross-sections, other shapes and cross-sections can also be used.
• the cavities may not necessarily comprise through cavities, i.e., the cavities may penetrate only one of the surfaces of the substrate.
• Fig. 2 is a schematic, cutaway illustration of microbattery 10, in accordance with an embodiment of the present invention, hi some embodiments, a first current collector layer 24 is formed over the surface area of substrate 20.
• Layer 24 typically comprises a metallic layer, which is deposited over substrate 20 using any suitable thin-film deposition process known in the art.
• layer 24 forms a hollow structure or crust that coats the entire surface area of the perforated substrate, both internally and externally to cavities 22. In particular, layer 24 coats the interior surfaces of cavities 22.
• Exemplary microbatteries in which layer 24 comprises a 2-4 micron nickel layer are described below. Alternatively, thinner (e.g., 1 micron) or thicker current collector layers can also be used.
• Current collector layer 24 forms one of the terminals of the microbattery.
• current collector 24 can be omitted.
• a carbon or metallic substrate may be sufficiently conductive so as to obviate the use of layer 24.
• a perforated metal sheet, a carbon (e.g., graphite) mesh or a highly doped silicon wafer may serve as electrically-conductive substrates .
• a cathode layer 26 is formed over the first current collector layer (or directly over the perforated substrate, if the first current collector layer is omitted). Layer 26 substantially coats the entire surface area of the first current collector, both internally and externally to cavities
• first current collector layer 24 When first current collector layer 24 is omitted, the cathode layer coats the substrate, and the substrate itself forms one of the terminals of microbattery 10.
• layer 26 comprises molybdenum oxysulfide
• cathode materials that may be used are described in U.S. Patent 6,197,450, and in PCT Patent Applications PCT/IL2004/000945 and PCT/IL2005/000414, cited above.
• alternative cathode materials may comprise FeS, FeS2, WS2, LiCoO 2 , LiNiO 2 , LiMn 2 O 4 , CuS 5 CuS 2 , TiS 2 , V 2 O 5 , V 3 O 8 , Lii +x Mn 2 _ y ⁇ 4, MoO 2 , MoO 3 ,
• an additional polymer is added to the cathode material to form a thicker, composite cathode.
• Composite cathodes are described, for example, by Golodnitsky et al. in "Progress in Three-Dimensional (3D) Li-Ion Microbatteries," The 15 International Conference on Solid State Ionics (SSI-15), Baden-Baden, Germany, July 17-22, 2005, which is incorporated herein by reference.
• Composite negative electrode configurations used in secondary batteries are described in U.S. Patent 5,162,178, whose disclosure is incorporated herein by reference.
• the thickness of composite cathodes used in the microbattery configurations described herein may vary from approximately 20 nm to over 10 microns, whereas the thickness of a pristine cathode may typically vary between 10 nm and 2 microns.
• a thicker cathode typically increases the energy density of the battery.
• Exemplary battery configurations comprising composite cathodes and associated energy density (capacity) test results are described below.
• the microbattery configurations described herein are particularly suitable for deploying composite cathodes because fewer battery layers are applied in the interior of the cavities. Thus, a larger cavity volume is available to support a thicker cathode.
• the cathode layer may be formed using an electrochemical deposition process or using any other suitable method, such as electroless deposition and chemical vapor deposition.
• the characteristic thickness of the cathode layer is in the range of 0.2 to 5 microns, although other thicknesses can also be used.
• layer 26 is formed so as to coat the entire surface of the first current collector or substrate.
• An electrolyte separator layer is applied over cathode layer 26 to form the separator layer of the microbattery, as is known in the art.
• the electrolyte separator layer comprises an ion-conducting electrolyte membrane 28.
• Membrane 28 is disposed so as to coat the cathode layer and fill the remaining interior volume of cavities 22.
• Membrane 28 extends beyond the outer surface (or surfaces) of substrate 20. Typically, such as in the example of Fig. 2, the membrane extends beyond both opposite faces of the substrate and has two opposite planar outer surfaces. As can be appreciated, membrane 28 is in contact with cathode layer 26 across a large surface area, both in the interior of the cathode-plated cavities and over the external faces of the cathode-plated substrate.
• membrane 28 comprises a hybrid polymer electrolyte (HPE).
• membrane 28 may comprise a ceramic or other solid electrolyte, a polymer electrolyte or a gel electrolyte.
• membrane 28 is electrically insulating and ion-conducting.
• the membrane material can be inserted into the cavities using any suitable process known in the art, such as spin-coating, vacuum-assisted pulling, pasting, pressure-filling and casting processes.
• substrate 20, cathode layer 26 and electrolyte membrane 28 should be chosen so as to be chemically compatible with one another, i.e., not react with one another or cause corrosion.
• anode layer 30 is formed on or otherwise attached to the outer surface or surfaces of the ion-conducting membrane.
• anode layer 30 comprises graphite.
• the anode may comprise any other suitable material, such as various lithium alloys known to reversibly intercalate with lithium and comprises one or more elements selected from: Si, Sn, Sb, Al, Mg, Cu, Ni and Co.
• the anode may alternatively comprise any other suitable alkali metal or alkali metal alloy.
• the anode layer comprises a substantially flat layer or film. The anode may be deposited onto the outer surface of the membrane using a thin- or thick-film deposition process.
• the anode may comprise a thin foil made of anode material and attached to the surface of the membrane.
• the anode layer may either be attached to one or both outer surfaces of membrane 28.
• a second current collector layer 32 is optionally attached to the anode layer and connected to another terminal of battery 10.
• the anode comprises an electrically-conductive material (such as graphite)
• the second current collector may be omitted and the battery terminal connected directly to the anode.
• the anode and second current collector are substantially flat, 2-D layers that do not penetrate into cavities 22.
• terminal 34A and 34B are connected to the first and second current collector layers, respectively.
• Terminal 34A is led through a suitable opening in the microbattery structure and connected to layer 24.
• Terminal 34B is connected to layer 32.
• terminal 34A is connected directly to substrate 20.
• terminal 34B is connected directly to anode layer 30.
• Fig. 3 is a schematic top view cross-section of microbattery 10 of Fig. 2 above, in accordance with an embodiment of the present invention.
• the figure shows a top view cross section in the horizontal plane marked III in Fig. 2 above, showing substrate 20 with cavities 22.
• the interior surfaces of the cavities are plated with first current collector layer 24, then with cathode layer 26.
• the remaining volume inside the cavities is filled with membrane 28.
• the structure of microbattery 10 shown in Figs. 2 and 3 is simpler to fabricate.
• the ion-conducting membrane can be allowed to fill the entire remaining volume of the cavities, without the need to accommodate an additional anode layer.
• the membrane can be applied using various filling, pasting and/or casting methods, and not necessarily using conformal deposition processes.
• the cathode layer can be made thicker, thus increasing the energy capacity of the battery.
• the microbattery may comprise an anode layer that coats the substrate, and a flat external cathode.
• Fig. 4 is a flow chart that schematically illustrates a method for fabricating microbattery 10, in accordance with an embodiment of the present invention. Several examples of specific microbatteries fabricated using the method of Fig. 4 are described further below. The method begins by producing or otherwise obtaining a perforated substrate
• the perforated substrate may be produced as part of the microbattery fabrication process.
• a suitable perforated substrate may be provided a-priori.
• first current collector layer 24 is deposited on the substrate, at a first current collector forming step 42. Then, the first electrode layer (in the present example a cathode layer) is formed, coating the first current collector layer, at a first electrode forming step 44. When the first current collector is omitted, the first electrode layer coats the substrate.
• Membrane 28 is then applied, at a membrane forming step 46.
• the membrane material fills the remaining volume of cavities 22 and extends beyond the 3-D structure of the substrate, forming one or two outer surfaces.
• a second electrode layer (in the present example an anode layer) is then applied to at least one of the outer surfaces of the membrane, at a second electrode forming step 48.
• second current collector layer in the present example an anode layer
• Terminals can then be connected to the microbattery, and the assembled microbattery can be packaged and/or sealed using any suitable means.
• Example 1 A 3-D microbattery is assembled in accordance with the configuration of Figs. 1-3 above.
• the microbattery comprises a M0S2 cathode, a hybrid polymer electrolyte (HPE) membrane and a lithium-ion graphite anode.
• a nickel layer is used as the cathode current collector.
• the substrate used in the present example comprises a round soda-lime MCP substrate (produced by BURLE Electro-Optics, Inc., part number Cl 3 S05M50).
• the substrate has an external diameter of 13mm, a thickness of 0.5mm, and has multiple round through cavities, 50 micron in diameter.
• the MCP substrate is made of soda-lime glass having the following composition (w/w%): SiO 2 (72.8), Na 2 O (13.7), CaO (8.8), MgO (4.0), Fe 2 O 3
• the substrate is initially treated to enhance the adhesion of the nickel current collector.
• the treatment comprises sequential soaking and degreasing in a detergent solution and ethanol, performed in an ultrasonic bath at room temperature.
• the substrate is subsequently immersed in boiling cyclohexane and concentrated (98%) sulfuric acid.
• the degreased surface is etched in a 1 :4 mixture of hydrofluoric (40%) and sulfuric (98%) acids.
• An electroless method known in the art to provide conformal coating, is used to deposit the nickel current collector on all exposed surfaces of the MCP substrate.
• the electroless deposition of nickel comprises several sequential repetitions of sensitization in a
• the activated nickel-plated substrate is immersed in an alkaline Ni-electroless bath with trisoduim citrate as a complexant and sodium hypophosphite as a reduction component.
• the autocatalytic process is carried out at 65-7O 0 C for 5-15 minutes.
• the thickness of the deposited nickel layer varies according to the deposition time. For example, 15 minutes of deposition produce a layer thickness of approximately 2 microns.
• the composition of the electroless solution is as follows: nickel sulfamate: 0.100M, sodium citrate: 0.125M, sodium acetate: 0.100M, sodium hypophosphite: 0.314M, thiourea: O.lmd/L, sodium dodecylsulfate: 10mg/L, pH: 9.
• the resulting current collector layer is conformal and highly adherent, completely coating the cavities.
• the electroless process described above yields a uniform 2-4 micron nickel layer both inside the cavities and on the external faces of the substrate.
• the nickel-plated substrate is washed with deionized water and then subjected to electrochemical cathode deposition.
• the electrochemical deposition process is carried out in
• the bath is prepared by mixing aqueous solutions of Na2S and Na2Mo ⁇ 4 and adjusting the pH of the solution to a value in the range 7.5-8.0 by adding HCl or KH2PO4.
• a flow control setup is used to ensure conformal deposition inside the high aspect ratio cavities.
• the nickel-plated substrate is placed between two graphite plates acting as counter-electrodes.
• a peristaltic pump provides a constant flow rate of up to 0.4
• a thin film M0S2 layer is obtained from electro-reduction of tetrathiomolybdate anions by applying a negative constant potential/current to the nickel- plated substrate.
• the HPE ion-conducting membrane comprises a commercially available PVDF-2801 copolymer (Kynar).
• Si ⁇ 2 (Aerosil 130) is added to the polymer matrix to enhance its ionic conductivity and electrolyte uptake.
• the PVDF powder is dissolved in high-purity cyclopentanone (Aldrich) or DMSO. Fumed silica 130 (Degussa) and propylene carbonate (PC, Merck) are then added, and the mixture is stirred at room temperature for approximately 24 hours to produce a homogeneous slurry.
• PEGDME can be used as a pore former.
• the thickness of the membrane and its morphology depends on the amount of solids in the casting slurry and on the type of solvent and pore former used.
• the membrane slurry is inserted into the cavities using several sequential spin-coating and vacuum pulling steps.
• the anode material is prepared.
• MCMB 6-28 (mesocarbon microbeads, Osaka Gas Corporation) is used as the anode lithium intercalation host material.
• the MCMB is dried at 200°C for approximately 8 hours.
• Anode slurry is prepared by mixing the appropriate amounts of MCMB, polymer binder and a solvent.
• the anode slurry is then pasted on the outer surface of the HPE membrane.
• a thin lithium film is applied with gentle pressure to the surface of the graphite anode to ensure intimate mating with the membrane.
• the lithiation of the graphite anode is preferably carried out within ten hours of the battery fabrication.
• microbattery is then soaked in IM UBF4 1 EC: 9 DEC electrolyte under vacuum, in order to ensure complete wetting of the materials.
• the microbattery is hermetically sealed in a 2324 coin cell.
• the LiC6.. x /HPE/MoS2 cells were cycled at room temperature using a Maccor series 2000 battery test system.
• the voltage cut-off was in the range of 1.3-2.4V.
• the Faradaic efficiency was close to 100%.
• Example 2 A 3-D microbattery is assembled similarly to example 1 above.
• the cathode layer comprises a thicker, composite cathode.
• MoS2-based cathode is produced using an electrochemical deposition process, by adding
• Fig. 5 is a graph showing a comparison between reversible capacities of 2-D and 3-D microbatteries having composite and pristine cathodes, in accordance with embodiments of 2 the present invention.
• the graph shows the capacity (energy density in mAh/cm ) as a function of the number of cycles for several exemplary microbatteries.
• Data points 54 show the capacity of a 3-D microbattery, assembled in accordance with example 2, having a pristine cathode. The capacity of this battery is shown to begin at ⁇ 1.5
• Data points 58 show the capacity of a comparable size battery having a composite
• Data points 62 show the capacity of a 2-D thin-film battery having a pristine cathode and the same footprint as the 3-D microbatteries described above.
• Data points 66 show the capacity of a comparable 2-D battery having a composite cathode. As can be seen in the figure, the capacity of a 3-D microbattery is an order of magnitude larger than the capacity of a comparable 2-D battery.
• Example 3 A 3-D microbattery is assembled similarly to example 2. In the present example, however, the composite cathode is deposited using an electrolyte having a 1:6 polymer-to-salt
• Fig. 6 is a graph showing a comparison between reversible capacities of 2-D and 3-D microbatteries having composite and pristine cathodes, in accordance with embodiments of the present invention.
• Data points 62 and 66 show the capacities of 2-D batteries having pristine and composite cathodes, respectively.
• Data points 70 show the capacity of the 3-D microbattery of example 3, whose composite cathode is deposited using an electrolyte having a 1 :6 polymer-to-salt ratio.
• a 3-D microbattery is assembled similarly to examples 1 and 2.
• the HPE membrane is cast only on one surface of the substrate.
• the resulting microbattery runs over 40 reversible cycles with a capacity loss of less than 0.1%/cycle. This example applies to both pristine and composite cathodes.
• a 3-D microbattery is assembled similarly to examples 1 and 2, with the HPE membrane cast on both surfaces of the MCP substrate.
• the cathode in this example comprises a composite -cathode.
• the microbattery has a reversible capacity of approximately
• Example 7 In order to avoid possible short circuits between the anode and cathode, an additional
• -P(EO ⁇ o polymer electrolyte can be applied by spin-coating to the two external faces of the MCP substrate, after the substrate had been coated with the nickel current collector and molybdenum oxysulfide cathode.
• a polymer slurry is prepared by dispersing known quantities of P(EO) and L1BF4, in analytical grade acetonitrile, together with the required amount of an inorganic filler, such as AI2O3 (Buehler) having an average diameter of approximately 150A.
• an ultrasonic bath or high-speed hor ⁇ ogenizer can be used. The suspension is stirred for approximately 24 hours before the PE films are cast on
• the fine polished Teflon support (having a 64 cm area).
• the solvent is allowed to evaporate slowly.
• the final thickness of the solvent-free PE films is in the range of 10-15 microns.
• PVDF-Si ⁇ 2 membrane insertion is carried out using a casting process and vacuum filling steps as in example 1 above.
• the degree of capacity degradation does not exceed 0.5%/cycle (100% DOD) when the Li/PEO-PVDF)/MoO x S y battery is
• a 3-D microbattery is assembled similarly to examples 1, 2 or 4.
• a Celgard 2400 separator is used as a polymer membrane.
• the resulting voltage cutoff is in the range of 1.3- 2 2.4V.
• the charge/discharge current density is 40 ⁇ A/cm .
• the battery delivers a capacity of
• Example 9 A 3-D microbattery is assembled on a silicon substrate.
• the battery comprises a lithium-ion anode, HPE membrane and a M0S2 cathode.
• the silicon substrate is immersed in an acetone and weak base solution for 5 minutes, and then washed in deionized water with successive immersion into a H 2 O 2 ⁇ Cl mixture for another 5 minutes. After rinsing in deinozed water, the substrate is etched in a NH4F:HF solution for 2 minutes, in order to roughen the silicon surface to increase the adherence of the current collector to the surface.
• Molybdenum oxysulfide is deposited on the substrate similarly to example 2 above.
• a commercially available PVDF-2801 copolymer (Kynar) is used as a binder, and fumed silica is used as filler for the polymer membrane.
• the battery is charged by a liquid Lilmide-ethylene carbonate (EC):dimethyl carbonate (DMC) 1:1 (v/v) electrolyte.
• EC Lilmide-ethylene carbonate
• DMC dimethyl carbonate
• the resulting 3-D lithium-ion/hybrid polymer electrolyte/MoS2 battery is cycled at room temperature using a Maccor series 2000 battery test system.
• the voltage cut-off is in the range of 1.2-2.3V.
• 2 density is in the range of 10-lOO ⁇ A/cm .
• the battery delivers a capacity of over 2mAh per
• the Faradaic efficiency is close to 100%.
• LiOH in aqueous phase
• HCL Hypoxia-sensitive LiOH
• the calculated number of moles of LiOH is subtracted from the initial number moles of Li-NM, to give the actual number of moles of lithium intercalated.
• Example 10 Several 3-D microbatteries having different electrochemically-deposited cathodes (CoO x Sy, FeOxS 2 - X , V 2 ⁇ 5_ x S x and Cu 2 S) are fabricated and tested.
• a Li/HPE/Cu 2 S 3-D microbattery having a 1 micron thick film cathode is assembled as described in example 1 above, starting with the following materials: 33 mg LiI, 216 mg P(EO), 41 mg EC, lOOmg AI2O3 .
• a 100% dense CU2S cathode is prepared by anodic oxidation of a metallic copper layer electrodeposited on the electroless nickel (or gold).
• the electrolyte for copper electrodeposition contains (g/L): 200-250 CUSO4X5H2O and 50-60 H2SO4.
• the electrolyte for copper electrodeposition contains (g/L): 200-250 CUSO4X5H2O and 50-60 H2SO4.
• 2 electrodeposition is performed at room temperature and a current density of 50 mA/cm for 8 minutes.
• the copper layer is electro-oxidized in an aqueous solution of polysulfides (a mixture of 1OmM Na2S 5 0.1M NaOH and elemental sulfur) at a constant current of 0.1-
• the principles of the present invention can also be used to fabricate other energy storage devices, such as double-layer capacitors (DLC) and other capacitor types.
• DLC double-layer capacitors

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• Battery Electrode And Active Subsutance (AREA)
• Electric Double-Layer Capacitors Or The Like (AREA)
• Cell Electrode Carriers And Collectors (AREA)
• Steroid Compounds (AREA)
• Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
• Cell Separators (AREA)

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• 2006
  • 2006-03-13 US US11/374,469 patent/US7618748B2/en not_active Expired - Fee Related
• 2007
  • 2007-02-07 DE DE602007007736T patent/DE602007007736D1/de active Active
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  • 2007-02-07 EP EP07706110A patent/EP1994592B1/en not_active Not-in-force
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