Hybrid thin-film battery

Abstract

An electrochemical device is claimed and disclosed wherein certain embodiments have a cathode greater than about 4 μm and less than about 200 μm thick; a thin electrolyte less than about 10 μm thick; and an anode less than about 30 μm thick. Another claimed and disclosed electrochemical device includes a cathode greater than about 0.5 μm and less than about 200 μm thick; a thin electrolyte less than about 10 μm thick; and an anode less than about 30 μm thick, wherein the cathode is fabricated by a non-vapor phase deposition method. A non-vacuum deposited cathode may be rechargeable or non-rechargeable. The cathode may be made of CF x (carbon fluoride) material, wherein, for example, 0<x<4. The electrochemical device may also include a substrate, a current collector, an anode current collector, encapsulation and a moderating layer.

1 . An electrochemical device comprising:
 a non-vapor phase deposited cathode;   a layer on the cathode;   an anode; and   a vapor phase deposited electrolyte deposited over the layer on said cathode, wherein the anode is positioned over the vapor phase deposited electrolyte.   
     
     
         2 . The electrochemical device of  claim 1 , further comprising an encapsulation layer deposited over said anode, the encapsulation layer comprising a ceramic-metal composite laminate. 
     
     
         3 . The electrochemical device of  claim 2 , wherein said ceramic-metal composite laminate is multiple alternating layers of (1) ceramic zirconium nitride and metal zirconium or (2) ceramic titanium mitride and metal titanium. 
     
     
         4 . The electrochemical device of  claim 2 , wherein said ceramic-metal composite laminate comprises metallic sub-layers comprising at least one element selected from the group consisting of: zirconium and titanium. 
     
     
         5 . The electrochemical device of  claim 4 , wherein said ceramic sub-layers comprise nitrides. 
     
     
         6 . The electrochemical device of  claim 2 , further comprising a modulating layer between the encapsulation layer and the anode. 
     
     
         7 . The electrochemical device of  claim 2 , wherein the encapsulation layer is at the periphery of said electrochemical device. 
     
     
         8 . The electrochemical device of  claim 1 , further comprising a flexible circuit board, wherein said electrochemical device is positioned on the flexible circuit board. 
     
     
         9 . The electrochemical device of  claim 1 , wherein said cathode comprises LiCoO 2 , said electrolyte comprises Lithium Phosphorus Oxynitride (LiPON), and said anode comprises Lithium. 
     
     
         10 . The electrochemical device of  claim 1 , wherein said anode is lithium. 
     
     
         11 . The electrochemical device of  claim 1 , wherein said electrolyte is Lithium Phosphorus Oxynitride (LiPON). 
     
     
         12 . The electrochemical device of  claim 1 , wherein said cathode is LiCoO 2 . 
     
     
         13 . The electrochemical device of  claim 1 , further comprising a substrate. 
     
     
         14 . The electrochemical device of  claim 1 , wherein said electrolyte is a thin-film electrolyte. 
     
     
         15 . The electrochemical device of  claim 1 , wherein said electrolyte comprises Lithium Phosphorus Oxynitride (LiPON). 
     
     
         16 . The electrochemical device of  claim 1 , wherein said electrolyte is deposited directly on said cathode. 
     
     
         17 . The electrochemical device of  claim 1 , wherein said electrochemical device is encapsulated with a material selected from ceramic multi-layer thin-film encapsulate, polymer composite, metal foil, adhesive, and metal can. 
     
     
         18 . The electrochemical device of  claim 1 , wherein said electrochemical device is encapsulated with an encapsulation grown by a vacuum vapor phase process. 
     
     
         19 . The electrochemical device of  claim 18 , wherein said encapsulation consists of a multilayer stack of inorganic compounds and metals. 
     
     
         20 . The electrochemical device of  claim 18 , wherein said encapsulation is separated from the negative anode by an interposed modulation layer. 
     
     
         21 . The electrochemical device of  claim 1 , further comprising a cathode current collector. 
     
     
         22 . The electrochemical device of  claim 1 , further comprising an anode current collector.