Abstract: In accordance with the present invention, deposition of LiCoO2 layers in a pulsed-dc physical vapor deposition process is presented. Such a deposition can provide a low-temperature, high deposition rate deposition of a crystalline layer of LiCoO2 with a desired (101) or (003) orientation. Some embodiments of the deposition addresses the need for high rate deposition of LiCoO2 films, which can be utilized as the cathode layer in a solid state rechargeable Li battery. Embodiments of the process according to the present invention can eliminate the high temperature (>700° C.) anneal step that is conventionally needed to crystallize the LiCoO2 layer. Some embodiments of the process can improve a battery utilizing the LiCoO2 layer by utilizing a rapid thermal anneal process with short ramp rates.

Abstract: The present invention relates to, for example, printed circuit boards having a thin film battery or other electrochemical cell between or within its layer or layers. The present invention also relates to, for example, electrochemical cells within a layer stack of a printed circuit board.

Abstract: Methods of integrating an electrochemical device to a fixture are disclosed. When performed, these methods may, for example, result in the improved performance and/or extended shelf life of the electrochemical device. These methods may include, for example, discharging an electrochemical device prior to an integration process, limiting the temperature exposure of the electrochemical device during the integration process, and/or applying a constraining force to a surface of the electrochemical device during an integration process.

Abstract: The present invention relates to metal foil encapsulation of an electrochemical device. The metal foil encapsulation may also provide contact tabs for the electrochemical device. The present invention may also include a selectively conductive bonding layer between a contact and a cell structure.

Abstract: The present invention relates to apparatus, compositions and methods of fabricating high performance thin-film batteries on metallic substrates, polymeric substrates, or doped or undoped silicon substrates by fabricating an appropriate barrier layer composed, for example, of barrier sublayers between the substrate and the battery part of the present invention thereby separating these two parts chemically during the entire battery fabrication process as well as during any operation and storage of the electrochemical apparatus during its entire lifetime. In a preferred embodiment of the present invention thin-film batteries fabricated onto a thin, flexible stainless steel foil substrate using an appropriate barrier layer that is composed of barrier sublayers have uncompromised electrochemical performance compared to thin-film batteries fabricated onto ceramic substrates when using a 700° C. post-deposition anneal process for a LiCoO2 positive cathode.

Abstract: The present invention relates to apparatus, compositions and methods of fabricating high performance thin-film batteries on metallic substrates, polymeric substrates, or doped or undoped silicon substrates by fabricating an appropriate barrier layer composed, for example, of barrier sublayers between the substrate and the battery part of the present invention thereby separating these two parts chemically during the entire battery fabrication process as well as during any operation and storage of the electrochemical apparatus during its entire lifetime. In a preferred embodiment of the present invention thin-film batteries fabricated onto a thin, flexible stainless steel foil substrate using an appropriate barrier layer that is composed of barrier sublayers have uncompromised electrochemical performance compared to thin-film batteries fabricated onto ceramic substrates when using a 700° C. post-deposition anneal process for a LiCoO2 positive cathode.

Abstract: The present invention relates to apparatus, compositions and methods of fabricating high performance thin-film batteries on metallic substrates, polymeric substrates, or doped or undoped silicon substrates by fabricating an appropriate barrier layer composed, for example, of barrier sublayers between the substrate and the battery part of the present invention thereby separating these two parts chemically during the entire battery fabrication process as well as during any operation and storage of the electrochemical apparatus during its entire lifetime. In a preferred embodiment of the present invention thin-film batteries fabricated onto a thin, flexible stainless steel foil substrate using an appropriate barrier layer that is composed of barrier sublayers have uncompromised electrochemical performance compared to thin-film batteries fabricated onto ceramic substrates when using a 700° C. post-deposition anneal process for a LiCoO2 positive cathode.

Abstract: An electrochemical device is claimed and disclosed, including a method of manufacturing the same, comprising an environmentally sensitive material, such as, for example, a lithium anode; and a plurality of alternating thin metallic and ceramic, blocking sub-layers. The multiple metallic and ceramic, blocking sub-layers encapsulate the environmentally sensitive material. The device may include a stress modulating layer, such as for example, a Lipon layer between the environmentally sensitive material and the encapsulation layer.

Abstract: The invention relates to a solid-state lithium-ion thin-film electrolyte that, compared to the current state-of-the-art thin-film electrolyte, Lipon, exhibits an equal or larger electrochemical stability window (0-5.5 V vs. Li+/Li), an equal or smaller electronic conductivity (10?14 S/cm at 25° C.), the same ideal transference number for Li+ ions (t=1.000), and a 10× higher Li+ ion conductivity at ?40° C. Latter provides thin-film batteries (TFBs) with at least a 5× higher power performance at ?40° C. over the current state-of-the-art Lipon TFBs.

Abstract: Alternative sputter target compositions or configurations for thin-film electrolytes are proposed whereby the sputter target materials system possesses sufficient electrical conductivity to allow the use of (pulsed) DC target power for sputter deposition. The electrolyte film materials adopt their required electrically insulating and lithium-ion conductive properties after reactive sputter deposition from the electrically conducting sputter target materials system.

Abstract: An electrochemical device is claimed and disclosed wherein certain embodiments have a cathode greater than about 4 ?m and less than about 200 ?m thick; a thin electrolyte less than about 10 ?m thick; and an anode less than about 30 ?m thick. Another claimed and disclosed electrochemical device includes a cathode greater than about 0.5 ?m and less than about 200 ?m thick; a thin electrolyte less than about 10 ?m thick; and an anode less than about 30 ?m 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 CFx (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.

Abstract: The present invention relates to metal film encapsulation of an electrochemical device. The metal film encapsulation may provide contact tabs for the electrochemical device. The present invention may also include a selectively conductive bonding layer between a contact and a cell structure. The present invention may further include ways of providing heat and pressure resilience to the bonding layer and improving the robustness of the protection for the cell structure.

Abstract: A method of forming a lithium orthophosphate sputter target or tile and resulting target material is presented. The target is fabricated from a pure lithium orthophosphate powder refined to a fine powder grain size. After steps of consolidation into a ceramic body, packaging and degassing, the ceramic body is densified to high density, and transformed into a stable single phase of pure lithium orthophosphate under sealed atmosphere. The lithium orthophosphate target is comprised of a single phase, and can preferably have a phase purity greater than 95% and a density of greater than 95%.

Abstract: An apparatus for use as a fracture absorption layer, an apparatus for use as a electrochemical device, and methods of manufacturing the same are taught. The apparatuses and methods of the present invention may be of particular use in the manufacture of thin-film, lightweight, flexible or conformable, electrochemical devices such as batteries, and arrays of such devices. The present invention may provide many advantages including stunting fractures in a first electrochemical layer from propagating in a second electrochemical layer.

Abstract: Methods of manufacturing an electrochemical device, are taught. The methods may be of particular use in the manufacture of thin-film, lightweight, flexible or conformable, electrochemical devices such as batteries, and arrays of such devices. The methods may provide many advantages including stunting fractures in a first electrochemical layer from propagating in a second electrochemical layer.

Abstract: The manufacture and use of multilayer thin-film batteries, such as inverted lithium-free batteries is explained. The present invention provides a battery that may include a lithium vanadium oxide LixV2Oy (0<x≦100, 0<y≦5) positive cathode or negative anode. The present invention may also provide for a thin-film battery that may be formed on a wide variety of substrate materials and geometries.

Abstract: An apparatus for use as a fracture absorption layer, an apparatus for use as a electrochemical device, and methods of manufacturing the same are taught. The apparatuses and methods of the present invention may be of particular use in the manufacture of thin-film, lightweight, flexible or conformable, electrochemical devices such as batteries, and arrays of such devices. The present invention may provide many advantages including stunting fractures in a first electrochemical layer from propagating in a second electrochemical layer.

Abstract: The manufacture and use of multilayer functional thin-film devices, such as solid-state thin-film batteries, including lithium thin-film batteries on unconventional substrate geometries integrated into multifunctional materials is described. The unconventional geometries may include fibers, ribbons, and strips, which may be woven together or held together in matrices of material to form structural or other multifunctional composites with, for example, integrated power.

Abstract: The fabrication of functional thin-film patterns, such as solid-state thin-film batteries on substrates having fibrous, or ribbon-like or strip-like geometry is disclosed. The present invention relates additionally to the design and manufacture of multiple-layer and multi-function thin films.

Abstract: The present invention relates to patterned thin film electrochemical devices such as batteries on fibrous or ribbon-like substrates, as well as the design and manufacture of the same, for utilization in electrochemical cells, electronic devices, optical devices, synthetic multi-functional materials, and superconducting materials, as well as fiber reinforced composite material applications.