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Register a new userThree-Dimensional Solid-State Lithium-Ion Batteries Fabricated Via Conformal Vapor-Phase Chemistry
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Thin film solid state lithium-based batteries (TSSBs) are increasingly attractive for their intrinsic safety due to the use of a nonflammable solid electrolyte, cycling stability, and ability to be easily patterned in small form factors. However, existing methods for fabricating TSSBs are limited to planar geometries, which severely limits areal energy density when the electrodes are kept sufficiently thin to achieve high areal power. In order to circumvent this limitation, we report the first successful fabrication of fully conformal, 3D full cell TSSBs formed in micromachined silicon substrates with aspect ratios up to ~10 using atomic layer deposition (ALD) at low processing temperatures (at or below 250C) to deposit all active battery components. The cells utilize a prelithiated LiV$_2$O$_5$ cathode, a very thin (40 - 100 nm) LiPON-like lithium polyphosphazene (Li$_2$PO$_2$N) solid electrolyte, and a SnN$_x$ conversion anode, along with Ru and TiN current collectors. Planar all-ALD solid state cells deliver 37 {mu}Ah/cm$^2${mu}m normalized to the cathode thickness with only 0.02% per-cycle capacity loss for hundreds of cycles. Fabrication of full cells in 3D substrates increases the areal discharge capacity by up to a factor of 9.3x while simultaneously improving the rate performance, which corresponds well to trends identified by finite element simulations of the cathode film. This work shows that the exceptional conformality of ALD, combined with conventional semiconductor fabrication methods, provides an avenue for the successful realization of long-sought 3D TSSBs which provide power performance scaling in regimes inaccessible to planar form factor devices.
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The existence of passivating layers at the interfaces is a major factor enabling modern lithium-ion (Li-ion) batteries. Their properties determine the cycle life, performance, and safety of batteries. A special case is the solid electrolyte interphase (SEI), a heterogeneous multi-component film formed due to the instability and subsequent decomposition of the electrolyte at the surface of the anode. The SEI acts as a passivating layer that hinders further electrolyte disintegration, which is detrimental to the Coulombic efficiency. In this work, we use first-principles simulations to investigate the kinetic and electronic properties of the interface between lithium fluoride (LiF) and lithium carbonate (Li$_2$CO$_3$), two common SEI components present in Li-ion batteries with organic liquid electrolytes. We find a coherent interface between these components that restricts the strain in each of them to below 3%. We find that the interface causes a large increase in the formation energy of the Frenkel defect, generating Li vacancies in LiF and Li interstitials in Li$_2$CO$_3$ responsible for transport. On the other hand, the Li interstitial hopping barrier is reduced from $0.3$ eV in bulk Li$_2$CO$_3$ to $0.10$ or $0.22$ eV in the interfacial structure considered, demonstrating the favorable role of the interface. Controlling these two effects in a heterogeneous SEI is crucial for maintaining fast ion transport in the SEI. We further perform Car-Parrinello molecular dynamics simulations to explore Li ion conduction in our interfacial structure, which reveal an enhanced Li ion diffusion in the vicinity of the interface. Understanding the interfacial properties of the multiphase SEI represents an important frontier to enable next-generation batteries.
In the lithium-ion battery literature, discharges followed by a relaxation to equilibrium are frequently used to validate models and their parametrizations. Good agreement with experiment during discharge is easily attained with a pseudo-two-dimensional model such as the Doyle-Fuller-Newman (DFN) model. The relaxation portion, however, is typically not well-reproduced, with the relaxation in experiments occurring much more slowly than in models. In this study, using a model that includes a size distribution of the active material particles, we give a physical explanation for the slow relaxation phenomenon. This model, the Many-Particle-DFN (MP-DFN), is compared against discharge and relaxation data from the literature, and optimal fits of the size distribution parameters (mean and variance), as well as solid-state diffusivities, are found using numerical optimization. The voltage after relaxation is captured by careful choice of the current cut-off time, allowing a single set of physical parameters to be used for all C-rates, in contrast to previous studies. We find that the MP-DFN can accurately reproduce the slow relaxation, across a range of C-rates, whereas the DFN cannot. Size distributions allow for greater internal heterogeneities, giving a natural origin of slower relaxation timescales that may be relevant in other, as yet explained, battery behavior.
Quantum chemistry simulations of four industrially relevant molecules are reported. Dissociation curves and dipole moments are reported for lithium hydride (LiH), hydrogen sulfide (H2S), lithium hydrogen sulfide (LiSH) and lithium sulfide (Li2S). Herein, we demonstrate the ability to calculate dipole moments using up to 21 qubits on a quantum simulator for a lithium sulfur salt molecule, and demonstrate the ability to calculate the dipole moment of the LiH molecule on the IBM Q Valencia device using four qubits. This is the first example to the best of our knowledge of dipole moment calculations being performed on quantum hardware.
Several active areas of research in novel energy storage technologies, including three-dimensional solid state batteries and passivation coatings for reactive battery electrode components, require conformal solid state electrolytes. We describe an atomic layer deposition (ALD) process for a member of the lithium phosphorus oxynitride (LiPON) family, which is employed as a thin film lithium-conducting solid electrolyte. The reaction between lithium tert-butoxide (LiO$^t$Bu) and diethyl phosphoramidate (DEPA) produces conformal, ionically conductive thin films with a stoichiometry close to Li$_2$PO$_2$N between 250 and 300$^circ$C. The P/N ratio of the films is always 1, indicative of a particular polymorph of LiPON which closely resembles a polyphosphazene. Films grown at 300$^circ$C have an ionic conductivity of $6.51:(pm0.36)times10^{-7}$ S/cm at 35$^circ$C, and are functionally electrochemically stable in the window from 0 to 5.3V vs. Li/Li$^+$. We demonstrate the viability of the ALD-grown electrolyte by integrating it into full solid state batteries, including thin film devices using LiCoO$_2$ as the cathode and Si as the anode operating at up to 1 mA/cm$^2$. The high quality of the ALD growth process allows pinhole-free deposition even on rough crystalline surfaces, and we demonstrate the fabrication and operation of thin film batteries with the thinnest (<100nm) solid state electrolytes yet reported. Finally, we show an additional application of the moderate-temperature ALD process by demonstrating a flexible solid state battery fabricated on a polymer substrate.
A thick electrode with high areal capacity has been developed as a strategy for high-energy-density lithium-ion batteries, but thick electrodes have difficulties in manufacturing and limitations in ion transport. Here, we reported a new manufacturing approach for ultra-thick electrode with aligned structure, called structure electrode additive manufacturing or SEAM, which aligns active materials to the through-thicknesses direction of electrodes using shear flow and a designed printing path. The ultra-thick electrodes with high loading of active materials, low tortuous structure, and good structure stability resulting from a simple and scalable SEAM lead to rapid ion transport and fast electrolyte infusion, delivering a higher areal capacity than slurry-casted thick electrodes. SEAM shows strengths in design flexibility and scalability, which allows the production of practical high energy/power density structure electrodes.
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