Electrophoretic deposition of thin film batteries

Abstract

Methods for forming three-layer thin-film battery (TFB) structures by sequential electrophoretic deposition (EPD) on a single conductive substrate. The TFBs may be two-dimensional or three-dimensional. The sequential EPD includes EPD of a first battery electrode followed by EPD of a porous separator on the first electrode and by EPD of a second battery electrode on the porous separator. In some embodiments of a Li or Li-ion TFB, the separator includes a Li ion conducting solid. In some embodiments of a Li or Li-ion TFB, the separator includes an inorganic porous solid rendered ionically conductive by impregnation with a liquid or polymer. In some embodiments, the TFBs are coated and sealed with an EPDd PEEK layer.

What is claimed is: 
     
         1 . A thin film battery (TFB) comprising two thin-film active material electrodes with opposite polarities separated by a composite ceramic hybrid electrolyte separator that includes an inorganic porous solid, at least one of the electrodes and the separator formed inside a through-hole of a perforated substrate, wherein the porous solid is partially penetrated by at least one of the active material electrodes at an interface therebetween. 
     
     
         2 . The TFB of  claim 1 , wherein both electrodes and the separator are formed at least inside the through hole of the perforated substrate. 
     
     
         3 . The TFB of  claim 1 , wherein the at least one electrode and the separator form a concentric microbattery structure. 
     
     
         4 . The TFB of  claim 2 , wherein the two electrodes and the separator form a concentric microbattery structure. 
     
     
         5 . The TFB of  claim 1 , wherein the porous solid comprises ZrO 2  (8% Y 2 O 3 ). 
     
     
         6 . The TFB of  claim 1 , wherein the porous solid is a lithium ion conducting solid. 
     
     
         7 . The TFB of  claim 1 , wherein the porous solid comprises a glass-ceramic. 
     
     
         8 . The TFB of  claim 1 , wherein the porous solid comprises LiAlO 2 . 
     
     
         9 . The TFB of  claim 1 , further comprising an external PEEK coating. 
     
     
         10 . The TFB  claim 2 , wherein one active material electrode comprises LiFePO 4  and the other active material electrode comprises MCMB. 
     
     
         11 . The TFB  claim 3 , wherein one active material electrode comprises LiFePO 4  and the other active material electrode comprises MCMB. 
     
     
         12 . The TFB  claim 4 , wherein one active material electrode comprises LiFePO 4  and the other active material electrode comprises MCMB. 
     
     
         13 . The TFB of  claim 5 , wherein one active material electrode comprises LiFePO 4  and the other active material electrode comprises MCMB. 
     
     
         14 . The TFB of  claim 7 , wherein the glass-ceramic Li 2 O—Al 2 O 3 —SiO 2 —P 2 O 5 —TiO 2 . 
     
     
         15 . The TFB of  claim 10 , further comprising a CuS topcoat over the LiFePO 4 .