U.S. patent application number 14/060387 was filed with the patent office on 2014-02-20 for method for manufacture and structure of multiple electrochemistries and energy gathering components within a unified structure.
This patent application is currently assigned to Sakti3, Inc.. The applicant listed for this patent is Sakti3, Inc.. Invention is credited to Fabio ALBANO, Ann Marie SASTRY, Chia Wei WANG.
Application Number | 20140050857 14/060387 |
Document ID | / |
Family ID | 42153257 |
Filed Date | 2014-02-20 |
United States Patent
Application |
20140050857 |
Kind Code |
A1 |
ALBANO; Fabio ; et
al. |
February 20, 2014 |
METHOD FOR MANUFACTURE AND STRUCTURE OF MULTIPLE ELECTROCHEMISTRIES
AND ENERGY GATHERING COMPONENTS WITHIN A UNIFIED STRUCTURE
Abstract
A method for using an integrated battery and device structure
includes using two or more stacked electrochemical cells integrated
with each other formed overlying a surface of a substrate. The two
or more stacked electrochemical cells include related two or more
different electrochemistries with one or more devices formed using
one or more sequential deposition processes. The one or more
devices are integrated with the two or more stacked electrochemical
cells to form the integrated battery and device structure as a
unified structure overlying the surface of the substrate. The one
or more stacked electrochemical cells and the one or more devices
are integrated as the unified structure using the one or more
sequential deposition processes. The integrated battery and device
structure is configured such that the two or more stacked
electrochemical cells and one or more devices are in electrical,
chemical, and thermal conduction with each other.
Inventors: |
ALBANO; Fabio; (Ann Arbor,
MI) ; WANG; Chia Wei; (Ypsilanti, MI) ;
SASTRY; Ann Marie; (Ann Arbor, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sakti3, Inc. |
Ann Arbor |
MI |
US |
|
|
Assignee: |
Sakti3, Inc.
Ann Arbor
MI
|
Family ID: |
42153257 |
Appl. No.: |
14/060387 |
Filed: |
October 22, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13465243 |
May 7, 2012 |
8597722 |
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14060387 |
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12614169 |
Nov 6, 2009 |
8192789 |
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13465243 |
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61112707 |
Nov 7, 2008 |
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Current U.S.
Class: |
427/446 ;
204/192.17; 205/59; 427/523; 427/575; 427/58; 427/596 |
Current CPC
Class: |
H01M 2300/0068 20130101;
H01M 4/0402 20130101; H01M 4/0421 20130101; Y02E 10/547 20130101;
H01M 4/0428 20130101; H01M 4/382 20130101; H01M 4/0423 20130101;
H01M 2008/1095 20130101; Y02E 60/50 20130101; H01M 12/08 20130101;
H01M 10/0562 20130101; H01M 12/005 20130101; Y02E 60/10 20130101;
H01M 4/045 20130101; Y10T 29/49115 20150115; H01M 4/5825 20130101;
H02S 40/38 20141201; H01M 10/04 20130101; Y10T 29/49108 20150115;
H01M 16/00 20130101; H01M 10/465 20130101; H01G 11/34 20130101;
H01L 31/022441 20130101; H01M 4/0426 20130101; H01L 31/1804
20130101; H01M 16/003 20130101; H01M 6/40 20130101; H01M 10/0436
20130101; H01M 16/006 20130101; H01M 4/505 20130101; H01M 4/0419
20130101; H01M 10/4264 20130101; Y02E 60/13 20130101 |
Class at
Publication: |
427/446 ; 205/59;
204/192.17; 427/58; 427/523; 427/596; 427/575 |
International
Class: |
H01M 12/00 20060101
H01M012/00; H01M 10/04 20060101 H01M010/04; H01M 12/08 20060101
H01M012/08; H01M 4/04 20060101 H01M004/04 |
Claims
1-16. (canceled)
17. A method for using an integrated battery and device structure,
the method comprising: providing two or more stacked
electrochemical cells integrated with each other formed overlying a
surface of a substrate, the two or more stacked electrochemical
cells comprising related two or more different electrochemistries;
and performing one or more sequential deposition processes in
forming one or more devices integrally with the two or more stacked
electrochemical cells to form the integrated battery and device
structure as a unified structure overlying the surface of the
substrate; whereupon the one or more stacked electrochemical cells
and the one or more devices are integrated as the unified structure
using the one or more sequential deposition processes; and wherein
the integrated battery and device structure is configured such that
the two or more stacked electrochemical cells and one or more
devices are in electrical, chemical, and thermal conduction with
each other; and using the integrated battery and device structure
in an energy system.
18. The method of claim 1 wherein the one or more sequential
deposition processes is one of at least evaporation, physical vapor
deposition (PVD), chemical vapor deposition (CVD), low pressure
chemical vapor deposition (LPCVD), electrochemical vapor deposition
(EVD), electroplating, atomic layer deposition (ALD), direct laser
writing (DLW), sputtering, radio frequency magnetron sputtering,
microwave plasma enhanced chemical vapor deposition (MPECVD),
pulsed laser deposition (PLD), nanoimprint, ion implantation, laser
ablation, spray deposition, spray pyrolysis, spray coating, plasma
spraying, sol/gel dipping spinning or sintering.
19. A method for using an integrated battery and device structure,
the method comprising: forming, using physical vapor deposition
processes using one or more sequential deposition processes, two or
more electrochemical cells integrated with each other overlying a
surface of a substrate, the two or more electrochemical cells
comprising related two or more different electrochemistries, the
two or more electrochemical cells being two or more different
electrochemistries in a stacked configuration; and forming one or
more devices integrally with the two or more electrochemical cells
to form the integrated battery and device structure overlying the
surface of the substrate, wherein the integrated battery and device
structure is configured such that the two or more electrochemical
cells and one or more devices are in electrical, chemical, and
thermal conduction with each other; wherein the one or more
electrochemical cells and the one or more devices are integrated as
a unified structure using the one or more sequential deposition
processes that forms the unified structure; wherein the two or more
electrochemical cells are configured as the stack in series and/or
in parallel; and using the integrated battery and device structure
in an energy system.
20. The method of claim 3 further comprising a separation region
configured for heat transfer provided between the two or more
electrochemical cells.
21. The method of claim 4 wherein the separation region configured
for thermal transfer is formed from at least diamond (C),
poly-diamond (poly-C), alumina, boron nitride, aluminum nitride, or
silicon carbide.
22. The method of claim 1 wherein the two or more
electrochemistries selected from at least lithium (Li),
lithium-ion, lithium-metal-polymer (LiM-polymer), lithium (Li)-air,
lead (Pb)-acid, nickel metal hydrate (Ni/MH), nickel-zinc (Ni/Zn),
zinc (Zn)-air, molten salts (Na/NiCl.sub.2), zebra (NaAlCl.sub.4),
nickel-cadmium (Ni/Cd), silver-zinc (Ag/Zn).
23. The method of claim 1 wherein the device comprises a
microelectromechanical system (MEMS) sensing element.
24. The method of claim 1 wherein the device comprises one or more
fuel-cells.
25. The method of claim 1 wherein the device comprises one or more
photovoltaics.
26. The method of claim 1 wherein the device comprises one or more
capacitors.
27. The method of claim 1 wherein the device comprises one or more
ultracapacitors.
28. The method of claim 1 wherein the device comprises a hybrid
combination of units selected from the group consisting of
electrochemical cells, fuel-cells, photovoltaic cells, capacitors,
ultracapacitors, piezoelectric, thermo-electric,
microelectromechanical turbines and energy scavengers.
29. The method of claim 1 further comprising a monitoring device
consisting of a data BUS in logic contact and communication with
the one or more devices and a central computing and processing unit
(CPU), the CPU having control over one or more individual
elements.
30. The method of claim 13 wherein the monitoring device is
configured to detect temperature T.
31. The method of claim 13 wherein the monitoring device is
configured to detect stress within one or more components.
32. The method of claim 13 wherein the monitoring device is
configured to detect gas and gaseous reaction by products from
operation at least either the one or more electrochemical cells or
one or more devices.
33. The method of claim 13 wherein the monitoring device is
configured to detect lithium composition and a transition through
an anode and a cathode separation layer.
34. The method of claim 1 further comprising one or more monitoring
devices to maintain a safe operation of the two or more
electrochemical cells or the one or more devices.
35. The method of claim 1 further comprising a cooling system
consisting of liquid coolant or liquefied gases activated if
temperature rises above a set threshold, the cooling system being
in thermal contact with heat sinks designed to remove thermal
energy using one or more conducting paths.
36. The method of claim 1 wherein the two or more electrochemical
cells is configured using hybrid principles applied to optimize
device architecture, schedule, energy and power density along with
rechargeability and lifetime.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This present application claims priority to and is a
continuation of U.S. patent application Ser. No. 13/465,243 filed
on May 7, 2012, which is a continuation of U.S. patent application
Ser. No. 12/614,169 filed on Nov. 6, 2009, which claims priority to
U.S. Provisional Patent Application No. 61/112,707 filed on Nov. 7,
2008, entitled "Method for manufacture and structure of multiple
electrochemistries and energy gathering components within a unified
structure," the disclosure of which is hereby incorporated by
reference in its entirety for all purposes.
SUMMARY OF THE INVENTION
[0002] According to the present invention, techniques related to
energy devices are provided. More particularly, embodiments of the
present invention relate to methods to design, manufacture, and
structure a multi-component energy device having a unified
structure. The individual components can include electrochemical
cells, photovoltaic cells, fuel-cells, capacitors, ultracapacitors,
thermoelectric, piezoelectric, micro electromechanical turbines, or
energy scavengers. The methods and systems described herein are
also applicable to a variety of energy systems.
[0003] According to an embodiment of the present invention, a
method for using an integrated battery and device structure is
provided. The method includes using two or more stacked
electrochemical cells integrated with each other formed overlying a
surface of a substrate. The two or more stacked electrochemical
cells include related two or more different electrochemistries with
one or more devices formed using one or more sequential deposition
processes. The one or more devices are integrated with the two or
more stacked electrochemical cells to form the integrated battery
and device structure as a unified structure overlying the surface
of the substrate. The one or more stacked electrochemical cells and
the one or more devices are integrated as the unified structure
using the one or more sequential deposition processes. The
integrated battery and device structure is configured such that the
two or more stacked electrochemical cells and one or more devices
are in electrical, chemical, and thermal conduction with each
other.
[0004] Numerous benefits are achieved by way of the present
invention over conventional techniques. For example,
electrochemical cells described herein present multiple chemistries
to accommodate a wider range of voltage and current compared to
individual ones. Additionally, energy-scavenging elements are
utilized to collect energy and replenish it to other components
within the unified structure. Depending upon the embodiment, one or
more of these benefits may be achieved. These and other benefits
will be described in more detail throughout the present
specification and more particularly below.
[0005] These and other objects and features of the present
invention and the manner of obtaining them will become apparent to
those skilled in the art, and the invention itself will be best
understood by reference to the following detailed description read
in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1--Simplified cross-sectional view of a unified
structure including an integrated silicon (Si) solar cell and a
thin film battery.
[0007] FIG. 2--Simplified cross-sectional view of a unified
structure including two integrated thin film batteries having
different chemistry.
[0008] FIG. 3--Simplified cross-sectional view of a unified
structure including an integrated hydrogen/oxygen fuel-cell and a
thin film battery.
[0009] FIG. 4--Simplified cross sectional view of a unified
structure including an integrated ultra-capacitor and a thin film
battery.
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
EXAMPLE 1
[0010] A Unified structure including a silicon (Si) solar cell and
a thin film battery and their manufacturing method.
[0011] Preparing a stacked cell on the back surface of a silicon
(Si) solar cell as shown in FIG. 1 can be achieved by forming the
cell components using physical vapor deposition. A solar cell
exploiting p-type silicon is constructed using traditional Si
wafers (Czochralski method). After forming a p-n junction by
diffusing phosphorous (P) into the wafer, an aluminum (Al) back
contact is created (metal back contact in FIG. 1), onto the p+
doped region (lower side) of the silicon wafer, using physical
vapor deposition. The aluminum layer is grown to a thickness of 1-2
.mu.m.
[0012] After the back metal contact is created, a separation layer
of electrically insulating and thermally conductive aluminum
nitride (AlN), having a thickness of 3-5 .mu.m, is fabricated onto
the aluminum layer using PVD. This layer has the function of
removing heat from the two elements and convey it to a heat
sink.
[0013] After the cooling element is completed, the battery
components are deposited sequentially and conformally by a physical
vapor deposition (PVD) process: an aluminum (Al) current collector
layer (1-3 .mu.m thick), a lithium manganese oxide
(LiMn.sub.2O.sub.4) cathode layer (3-5 .mu.m thick), a lithium
phosphorous oxynitride (LIPON) ceramic electrolyte layer (1-3 .mu.m
thick), a lithium (Li) metal anode layer (3-5 .mu.m thick), and a
copper (Cu) current collector layer (1-3 .mu.m thick),
respectively.
EXAMPLE 2
[0014] A Unified structure including two thin film batteries having
different chemistry and their manufacturing method.
[0015] Two stacked cells having different electrochemistries are
fabricated onto each other by using physical vapor deposition as
reported in FIG. 2.
[0016] The first battery components are deposited using a PVD
process onto an aluminum (Al) metal film used as cathode current
collector: a lithium iron phosphate (LiFePO.sub.4) cathode layer
(3-5 .mu.m thick), a lithium phosphorous oxynitride (LIPON) ceramic
electrolyte layer (1-3 .mu.m thick), a lithium (Li) metal anode
layer (3-5 .mu.m thick) and a copper (Cu) current collector layer
(1-3 .mu.m thick), respectively.
[0017] After the copper (Cu) metal current collector is created, a
separation layer of electrically insulating and thermally
conductive aluminum nitride (AlN), having a thickness of 3-5 .mu.m,
is fabricated onto the copper layer using PVD. This layer has the
function of removing heat from the two elements and convey it to a
heat sink.
[0018] After the cooling element is completed, the second battery
components are deposited sequentially and conformally by a PVD
process: an aluminum (Al) current collector layer (1-3 .mu.m
thick), a lithium manganese oxide (LiMn.sub.2O.sub.4) cathode layer
(3-5 .mu.m thick), a lithium phosphorous oxynitride (LIPON) ceramic
electrolyte layer (1-3 .mu.m thick), a lithium (Li) metal anode
layer (3-5 .mu.m thick) and a copper (Cu) current collector layer
(1-3 .mu.m thick), respectively.
EXAMPLE 3
[0019] A Unified structure including a fuel-cell and a thin film
battery and their manufacturing method.
[0020] Preparing a stacked cell on the back surface of a
proton-exchange membrane (PEM) fuel-cell as shown in FIG. 3 can be
achieved by forming the cell components using physical vapor
deposition (PVD). A PEM fuel-cell exploiting proton exchange
membranes with high proton conductivity, employing
perfluorosulfonate ionomers electrolytes such as Nafion.RTM., is
constructed using traditional sol-gel methods for fabricating the
membrane and wet slurry for the electrodes.
[0021] After assembly of the fuel-cell a separation layer of
electrically insulating and thermally conductive aluminum nitride
(AlN), having a thickness of 3-5 .mu.m, is fabricated onto the
fuel-cell current collector using PVD. This layer has the function
of removing heat from the two elements and conveying it to a heat
sink.
[0022] After the cooling element is completed, the battery
components are deposited sequentially and conformally by a PVD
process. Respectively an aluminum (Al) current collector layer (1-3
.mu.m thick), a lithium manganese oxide (LiMn.sub.2O.sub.4) cathode
layer (3-5 .sub.lam thick), a lithium phosphorous oxynitride
(LIPON) ceramic electrolyte layer (1-3 .mu.m thick), a lithium (Li)
metal anode layer (3-5 .mu.m thick) and a copper (Cu) current
collector layer (1-3 .mu.m thick).
EXAMPLE 4
[0023] A Unified structure including an ultra-capacitor and a thin
film battery and their manufacturing method.
[0024] Preparing a stacked cell on the back surface of an
electrochemical double layer capacitor (EDLC), which is also known
as an ultra-capacitor) as shown in FIG. 3 can be achieved by
forming the cell components using PVD. In such a hybrid system, the
battery provides high energy density while the EDLC enables high
power capability in the system.
[0025] EDLCs describe a class of energy-storage devices that
incorporate active materials including high-surface-area carbons
(activated carbons), electroactive polymers, transition metal
oxides and nitrides. The separation materials include advanced
dielectrics, conventional and advanced polymer electrolytes and
ionic conducting materials. Electrodes arrangement can be symmetric
or anti-symmetric. In FIG. 4 an anti-symmetric electrode
arrangement is presented for the device electrodes. The electrodes
of the capacitor can be formed by high-surface-area materials such
as activated carbon of high capacitance redox-active materials such
as metal oxides (e.g. hydrous ruthenium oxides,
RuO.sub.20.5H.sub.2O) prepared by sol-gel methods with capacitance
up to 700 F/g. Using anti-symmetric electrodes and different anode
and cathode materials resulting in higher working voltages enhances
the energy-storage capability of this element.
[0026] After assembly of the ultra-capacitor a separation layer of
electrically insulating and thermally conductive aluminum nitride
(AlN), having a thickness of 3-5 .mu.m, is fabricated onto the
dielectric material layer using PVD. This layer has the function of
removing heat from the two elements and conveying it to a heat
sink.
[0027] After the cooling element is completed, the battery
components are deposited sequentially and conformally by a PVD
process: an aluminum (Al) current collector layer (1-3 .mu.m
thick), a lithium manganese oxide (LiMn.sub.2O.sub.4) cathode layer
(3-5 .mu.m thick), a lithium phosphorous oxynitride (LIPON) ceramic
electrolyte layer (1-3 .mu.m thick), a lithium (Li) metal anode
layer (3-5 .mu.m thick) and a copper (Cu) current collector layer
(1-3 .mu.m thick), respectively.
[0028] It is also understood that the examples and embodiments
described herein are for illustrative purposes only and that
various modifications or changes in light thereof will be suggested
to persons skilled in the art and are to be included within the
spirit and purview of this application and scope of the appended
claims.
* * * * *