High-performance thin-film battery with an interfacial layer

A solid-state lithium-based battery comprising:

• a continuous anode-side electrode comprising a first horizontal anode-side electrode finger portion, a vertical anode-side electrode portion and a second horizontal anode-side electrode finger portion, wherein the first and second horizontal anode-side electrode finger portions are spaced apart by a gap and wherein the first horizontal anode-side electrode finger portion contacts a bottom portion of a first sidewall of the vertical anode-side electrode portion, and the second horizontal anode-side electrode finger portion contacts a top portion of the first sidewall of the vertical anode-side electrode portion;
• a continuous aluminum oxide interfacial layer located on the sidewalls and topmost surface of first horizontal anode-side electrode finger portion, on the first sidewall of the vertical anode-side electrode portion, and on a bottommost surface, a sidewall surface and a topmost surface of the second horizontal anode-side electrode finger portion;
• a lithium-based solid-state electrolyte layer located on the continuous aluminum oxide interfacial layer;
• a lithiated cathode material layer located on the lithium-based solid-state electrolyte;
• and
• a cathode-side electrode located on the lithiated cathode material, wherein the cathode-side electrode comprises a first horizontal cathode-side electrode finger portion, a vertical cathode-side electrode portion and a second horizontal cathode electrode finger portion, the first horizontal cathode-side electrode finger portion contacts a middle portion of a first sidewall of the vertical cathode-side electrode portion, and the second horizontal cathode-side electrode finger portion contacts a top portion of the first sidewall of the vertical cathode-side electrode portion, and wherein the first horizontal cathode-side electrode finger portion, and a portion of each of the aluminum oxide interfacial layer, the lithium-based solid-state electrolyte and the lithiated cathode material layer are present in the gap, and the second horizontal cathode-side electrode finger portion is located above the second horizontal anode-side electrode finger portion.

A method of forming a solid-state lithium-based battery, the method comprising:

• forming an anode-side electrode on a physically exposed surface of a substrate;
• forming an aluminum oxide interfacial layer on the anode-side electrode;
• forming a lithium-based solid-state electrolyte layer on a physically exposed surface of the aluminum oxide interfacial layer;
• forming a lithiated cathode material layer on a physically exposed surface of the lithium-based solid-state electrolyte layer;
• and
• forming a cathode-side electrode on a physically exposed surface of the lithiated cathode material layer.

A method of forming a solid-state lithium-based battery, the method comprising:

• forming a continuous anode-side electrode on surface of a substrate, the continuous anode-side electrode comprising a first horizontal anode-side electrode finger portion, a vertical anode-side electrode portion and a second horizontal anode-side electrode finger portion, wherein the first and second horizontal anode-side electrode finger portions are spaced apart by a gap and wherein the first horizontal anode-side electrode finger portion contacts a bottom portion of a first sidewall of the vertical anode-side electrode portion, and the second horizontal anode-side electrode finger portion contacts a top portion of the first sidewall of the vertical anode-side electrode portion;
• forming a continuous aluminum oxide interfacial layer on the sidewalls and topmost surface of first horizontal anode-side electrode finger portion, on the first sidewall of the vertical anode-side electrode portion, and on a bottommost surface, a sidewall surface and a topmost surface of the second horizontal anode-side electrode finger portion;
• forming a lithium-based solid-state electrolyte layer on the aluminum oxide interfacial layer;
• forming a lithiated cathode material layer on the lithium-based solid-state electrolyte layer;
• and
• forming a cathode-side electrode on a physically exposed surface of the lithiated cathode material layer, wherein the cathode-side electrode comprises a first horizontal cathode-side electrode finger portion, a vertical cathode-side electrode portion and a second horizontal cathode electrode finger portion, the first horizontal cathode-side electrode finger portion contacts a middle portion of a first sidewall of the vertical cathode-side electrode portion, and the second horizontal cathode-side electrode finger portion contacts a top portion of the first sidewall of the vertical cathode-side electrode portion, and wherein the first horizontal cathode-side electrode finger portion, and a portion of each of the aluminum oxide interfacial layer, the lithium-based solid-state electrolyte and the lithiated cathode material layer are present in the gap, and the second horizontal cathode-side electrode finger portion is located above the second horizontal anode-side electrode finger portion.