Methods of forming rechargeable battery stacks containing a spalled cathode material
AssigneeInternational Business Machines Corporation
InventorsYun Seog Lee, Stephen W. Bedell, Joel P. de Souza, Devendra K. Sadana
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Abstract
Methods of forming high-capacity and high-performance rechargeable batteries are provided by forming a rechargeable battery stack that includes a spalled material structure that includes a spalled cathode material that is attached to a stressor material. The spalled cathode material may include a single crystalline or polycrystalline cathode material that is devoid of polymeric binders. The stressor material serves as a cathode current collector of the rechargeable battery stack.
Claims25
A method of forming a rechargeable battery stack, the method comprising:
- providing a cathode material substrate;
- forming a stressor layer on a physically exposed surface of the cathode material substrate;
- and
- performing a spalling process to remove a spalled cathode material layer from the cathode material substrate, wherein the spalled cathode material layer is attached to the stressor layer.
A method of forming a rechargeable battery stack, the method comprising:
- providing a cathode material substrate;
- forming a plurality of patterned spalling barrier layer portions on a physically exposed surface of the cathode material substrate, wherein each patterned spalling barrier layer portion is separated by a gap;
- forming a stressor layer on physically exposed surfaces of each patterned spalling barrier layer portion and within each gap;
- and
- performing a spalling process to remove spalled cathode material layer portions that are not protected by the patterned spalling barrier layer portions from the cathode material substrate, wherein the spalled cathode material layer portions are attached to the stressor layer, and each spalled cathode material layer portion has a shape of the gap.
A method of forming a rechargeable battery stack, the method comprising:
- providing a cathode material substrate;
- forming a plurality of patterned stressor layer portions on a physically exposed surface of the cathode material substrate, wherein each patterned stressor layer portion is separated by a gap;
- and
- performing a spalling process to remove spalled cathode material layer portions from the cathode material substrate, wherein each spalled cathode material layer portion is attached to one of the stressor layer portions.
Dependencies are inferred from the claim text.