Rechargeable battery

Abstract

A rechargeable battery includes at least an electrolyte layer, a cathode layer and an anode layer. The electrolyte layer includes a lithium salt compound arranged between a cathode surface of the cathode layer and an anode surface of the anode layer. The anode layer is a nanostructured silicon containing thin film layer including a plurality of columns, wherein the columns are directed in a first direction perpendicular or substantially perpendicular to the anode surface of the silicon thin film layer. The columns are arranged adjacent to each other while separated by grain-like column boundaries running along the first direction. The columns include silicon and have an amorphous structure in which nano-crystalline regions exist.

1 . A rechargeable battery comprising:
 at least an electrolyte layer;   a cathode layer; and   an anode layer that is a nanostructured thin film layer comprising a plurality of adjacent columns extending in a perpendicular direction from an anode surface of the anode layer, the adjacent columns being separated by column boundaries extending in the perpendicular direction, the adjacent columns comprising silicon and having an amorphous structure in which nano-crystalline regions exist,   wherein the at least one electrolyte layer comprises a lithium salt compound disposed between a cathode surface of the cathode layer and the anode surface of the anode layer.   
     
     
         2 . The rechargeable battery according to  claim 1 , wherein the adjacent columns comprise up to 80% of nano-crystalline silicon. 
     
     
         3 . The rechargeable battery according to  claim 1 , wherein the adjacent columns further consist of amorphous silicon. 
     
     
         4 . The rechargeable battery according to  claim 1 , wherein the adjacent columns further comprise a silicon alloy. 
     
     
         5 . The rechargeable battery according to  claim 4 , wherein the silicon alloy has an amorphous structure. 
     
     
         6 . The rechargeable battery according to  claim 4 , wherein the silicon alloy is selected from a group of alloys comprising Si—C, Si—N, Si—Ge, Si—Ag, and Si—Sn. 
     
     
         7 . The rechargeable battery according to  claim 1 , wherein the nanostructured thin film layer has a porosity of about 30% to about 60%. 
     
     
         8 . The rechargeable battery according to  claim 1 , wherein the column boundaries form diffusion paths for Li ions during intercalation and deintercalation. 
     
     
         9 . The rechargeable battery according to  claim 1 , wherein the adjacent columns are elongated in the perpendicular direction. 
     
     
         10 . The rechargeable battery according to  claim 9 , wherein the adjacent columns have a length in the perpendicular direction of about 0.1 µm to about 10 µm. 
     
     
         11 . The rechargeable battery according to  claim 9 , wherein the adjacent columns have a length in the perpendicular direction of about 3 µm to about 8 µm. 
     
     
         12 . The rechargeable battery according to  claim 9 , wherein the adjacent columns have an average footprint of about 0.25 to about 0.5 µm 2 , along a surface of the nanostructured thin film layer. 
     
     
         13 . The rechargeable battery according to  claim 1 , wherein the nanostructured thin film layer is disposed on a substrate comprising a metallic conductor layer. 
     
     
         14 . The rechargeable battery according to  claim 1 , wherein the nanostructured thin film layer comprises n-type or p-type dopants. 
     
     
         15 . The rechargeable battery according to  claim 1 , wherein the column boundaries resemble grain-like column boundaries. 
     
     
         16 . The rechargeable battery according to  claim 1 , wherein the nanostructured thin film layer comprises, at least in part, free space between the plurality of silicon columns. 
     
     
         17 . The rechargeable battery according to  claim 1 , wherein the silicon columns comprise dendritic or multibranch silicon columns. 
     
     
         18 . The rechargeable battery according to  claim 1 , wherein the spatial distribution or arrangement of the plurality of silicon columns is a substantially random distribution across the anode layer. 
     
     
         19 . The rechargeable battery according to  claim 1 , wherein the nanostructured thin film layer is substantially porous.