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Encapsulation System For Electronic Components And Batteries

Abstract: The invention relates to a system (30) for encapsulating an object (1000), such as an electronic or electrochemical component such a a battery. The system is characterised in that it is formed by three successive layers comprising: (i) a first cover layer (31, 31') consisting of an electrically insulating material deposited by means of atomic layer deposition, which at least partially covers the object; (ii) a second cover layer (32, 32’) comprising parylene and/or polyimide, disposed on the first cover layer; (iii) a third cover layer (33, 33’) deposited on the second cover layer such as to protect the second encapsulation layer, in particular against oxygen and to increase the service life of the object.

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Patent Information

Application #
Filing Date
21 December 2019
Publication Number
07/2020
Publication Type
INA
Invention Field
ELECTRICAL
Status
Email
joginder@lexorbis.com
Parent Application
Patent Number
Legal Status
Grant Date
2021-11-23
Renewal Date

Applicants

I-TEN
12 chemin du Jubin 69570 Dardilly

Inventors

1. GABEN, Fabien
5 montée du Clair 69570 Dardilly

Specification

Technical Field of the Invention The present invention relates to the encapsulation of objects of systems such as microelectronic components and batteries. It more particularly the field of batteries, including lithium ion batteries, which can be encapsulated in this way. The invention also relates to a new method of manufacturing batteries thin film lithium ion, with a new architecture, and encapsulation which give them a particularly low self-discharge, and improved life. State of the art Microelectronic components and batteries, and in particular thin film batteries, must be encapsulated to be sustainable because oxygen and moisture degrade them. In particular, lithium ion batteries are very sensitive to moisture and require encapsulation which ensures a lifespan of over 10 years. With the spread of portable electronic devices and autonomous sensor networks, the need for rechargeable batteries with high energy density and high power density has increased considerably. The lithium ion thin film batteries have a high energy density and high power density, are rechargeable and have no memory effect: they are able to meet this need, The lithium ion thin film batteries include electrodes and a completely solid electrolyte, that is to say liquid-free. The thickness of the various layers which constitute the normally not exceed 10 μηη, and is often between 1 and 4 μηη. It is observed that these thin film batteries, such as multilayer batteries are susceptible to self-discharge. Depending on the positioning of the electrodes, including the proximity of the edges of the electrodes for multilayer batteries and cleanliness of the cutouts, a leakage current may appear on the ends, a creeping short-circuit which reduces the performance of the battery. This is exacerbated if the electrolyte film is very thin. These batteries in fully solid lithium ion thin film mostly use anodes having a metal lithium layer. It is observed that the anode materials have a high variation in their volume during cycles of charging and discharging the battery. Indeed, during a cycle of charging and discharging, a part of the metal lithium is transformed into lithium ions are inserted in the structure of cathode materials, which is accompanied by a reduction in the volume of 'anode. This cyclic variation of the volume can deteriorate the mechanical and electrical contact between the electrode and electrolyte layers. This decreases battery performance during his life. The cyclical variation of the volume of the anode materials also induces a cyclic variation in the volume of the battery cells. It thus creates cyclic stresses on the encapsulation system, which may initiate cracks that are causing the loss of sealing (or integrity) of the encapsulation system. This is another cause of the decline in battery performance during his life Indeed, the active materials of lithium ion batteries are very sensitive to air and particularly to moisture. Mobile lithium ions spontaneously react with traces of water to form LiOH, leading to a calendar aging batteries. All insertion materials and electrolyte lithium ion conductors are not reactive on contact with moisture. For example, Li 4 Ti 5 0 i 2 does not deteriorate on contact with the atmosphere or water marks. However, once it is loaded in form lithium in Li 4 + x Ti 5 0i 2with x> 0, then the surplus lithium inserted (x) is, in turn, sensitive to the atmosphere and spontaneously reacts with traces of water to form LiOH. Lithium reacted is then no longer available for electricity storage, leading to a loss of capacity of the battery. To avoid exposure of the active materials of the lithium ion battery to air and water and prevent this type of aging, it is essential to protect it with an encapsulation system. Many encapsulation systems for thin film batteries are described in the literature. Document US 2002/0071989 discloses an encapsulation of a battery thin film entirely solid system comprising a stack of a first layer of a dielectric material selected from alumina (Al 2 0 3 ), silica (Si0 2 ), silicon nitride (Si 3 N 4 ), silicon carbide (SiC), tantalum oxide (Ta 2 0 5 ) and the amorphous carbon, a second layer of dielectric material and a sealing layer disposed on the second layer and overlying the entire battery. US 5,561,004 describes several protection systems of a lithium ion battery in thin layers. A first proposed system comprises a layer of parylene coated with a deposited aluminum film on the active components of the drums. However, this system of protection against the spread of air and water vapor is only effective for about a month. A second proposed system comprises alternating layers of parylene (500 nm thick) and metal (about 50 nm thick). The states that document is preferable to coat these batteries still a cured epoxy layer with ultraviolet (UV) to reduce battery degradation rate by atmospheric elements. According to the prior art most of the lithium ion batteries are wrapped in metallized polymer sheets (called "pouch") closed around the battery cell and heat sealed at the strips (called "tabs") of connectors. These packages are relatively flexible and the positive and negative connections of the battery are then embedded in the heat-sealed polymer that was used to close the package around the battery. However, the weld between the sheets of polymer is not totally impervious to atmospheric gases, the polymers used to heat seal the battery are quite permeable to gases of the atmosphere. It is observed that the permeability increases with temperature, which accelerates the aging. However the surface of these welds exposed to the atmosphere is very low, and the rest of the packaging consists of aluminum sheets taken in sandwich between these polymer sheets. In general, two aluminum sheets are associated in order to minimize the effects related to the presence of holes, defects in each of the aluminum sheets. The probability of two defects, on each of the strips are aligned is greatly reduced. These technologies enable packaging to ensure approximately 10 to 15 years of calendar life for a battery of 10 Ah to 10 x 20 cm 2 surface under normal conditions of use. If the battery is exposed to high temperature, the lifetime may be reduced to less than 5 years; it is insufficient for many applications. Similar technologies can be used for other electronic components such as capacitors, active components. Accordingly, a need exists for systems and batteries encapsulation processes in thin films and other electronic components, which protect the component against air, moisture and temperature effects. In particular there is a need for systems and methods for encapsulating lithium ion thin film batteries, which protects against air and moisture as well as against deterioration when the battery is subjected to load cycles and discharge. The encapsulating system must be watertight and airtight, should wrap and completely cover the component or the battery must be sufficiently flexible to follow slight changes of dimensions ( "breathing") of the cell battery, and also serves to electrically separate the electrode edges of opposite signs in order to avoid creeping short-circuit. An objective of the present invention is to remedy at least in part the disadvantages of the prior art discussed above. Another objective of the present invention to provide lithium ion batteries with a very long life and having a low self-discharge. Objects of the Invention At least one of the above objectives is achieved through at least one of the objects of the invention as presented below. The present invention provides as a first object encapsulation system 30 of an object 1000 such as an electronic or electrochemical component such as a battery, characterized in that it is formed by three layers comprising i. a first cap layer 31, 31 'composed of an electrically insulating material deposited by atomic layer deposition (ALD hereinafter, acronym for Atomic Layer Deposition), which covers at least part of said object, ii. a second cover layer 32, 32 'comprising parylene and / or polyimide, disposed on the first cover layer, iii. a third cover layer 33, 33 'deposited on the second covering layer to protect the second encapsulation layer, in particular vis-à-vis oxygen, and increasing the lifetime of the object . Advantageously, the encapsulation system of an object comprises a covering layer comprising parylene and / or polyimide, preferably parylene N and an encapsulating system (30) deposited on said capping layer comprising parylene and / or polyimide. Advantageously, the third cap layer 33, 33 'is based on epoxy resin, polyethylene naphthalate (PEN), polyimide, polyamide, polyurethane or silicone. A second object of the invention is an electronic component such as a battery or electrochemical cell, preferably a thin film battery comprising an encapsulating system 30. Another object of the invention is an electrochemical component, said component being a thin film battery, said battery comprising a stack alternated between at least one anode 10, 10 'and at least one cathode 20, 20', each consisting of a stack of thin layers and in which the anode 10, 10 'comprises o at least one thin layer of an anode active material 12, and o optionally a thin layer of an electrolyte material 13, and wherein the cathode stack 20, 20'comprend o at least one thin layer of a cathode active material 22 and optionally o a thin layer of an electrolyte material 23 so that the battery pack comprises successively at least a thin layer of an anode active material 12 at least one thin layer of a 13,23 electrolyte material and at least one thin layer of a cathode active material 22, an encapsulation system 30 wherein said first layer 31, 31 'covers at least part of the stack, said encapsulating system 30 partially overlapping said stack, a first anode 10 or cathode 20 comprising at least one accessible connection area, while the cathode 20 or the anode 10 comprises an adjacent overlap region ZRT, which is covered by at least said first cap layer (31, 31 ') and said second cladding layer (32,32'), said overlap region being located opposite the ZC connection areas of the first anode or cathode in a direction perpendicular to plane of said stack. Another object of the invention is a method of manufacturing an electronic component encapsulated or electrochemical, comprising forming an encapsulation system 30 and which are successively deposited to form said encapsulating system 30: (I) a first layer 31, 31 'cover composed of an electrically insulating material by ALD, (Ii) a second outer layer 32,32 'comprising parylene and / or polyimide deposited on said first cladding layer, (Iii) a third covering layer 33,33 ', deposited on the second cladding layer, adapted to, and deposited so as to protect the second layer of encapsulation in particular oxygen. Another object of the invention is a method of manufacturing an electronic component or an encapsulated battery, comprising forming an encapsulation system according to the invention and wherein are successively deposited to form said system encapsulation: a pretreatment layer including parylene and / or polyimide on said electronic or electrochemical component, a first layer (31, 31 ') covering composed of an electrically insulating material by ALD deposited on said overcoat layer comprising parylene and / or polyimide, a second cladding layer (32,32 ') comprising parylene and / or polyimide deposited on said first cladding layer, a third cover layer (33,33 ') deposited on the second cladding layer, adapted to, and deposited so as to protect the second layer of encapsulation in particular oxygen. Still another object of the invention is a method of manufacturing a battery in thin layers, said battery comprising a stack alternated between at least one anode 10, 10 'and at least one cathode 20, 20', each consisting of a stack of thin layers and in which the anode 10, 10 'comprises, o at least one thin layer of an anode active material 12 and optionally o a thin layer of an electrolyte material 13, and wherein the cathode 20, 20 'comprises o at least one thin layer of a cathode active material 22 and optionally o a thin layer of an electrolyte material 23 so that the battery pack comprises successively at least a thin layer of an anode active material 12 at least one thin layer of a 13,23 electrolyte material and at least one thin layer of a cathode active material 22, said method comprising the steps of: (A) a primary overlay is formed, comprising an alternating succession of cathode sheet and anode sheet, said primary superposition being intended to form at least one battery, two adjacent sheets defining at least one protruding region RS, for forming said connection area accessible ZC, and at least one recessed region RT for forming said overlapping area PSTN, (B) depositing the encapsulation system of the invention by the method described above. Advantageously, after step (b), shows the connection area accessible ZC ZC or each available connecting area. In one embodiment, after step (b), a step is carried out (c) comprising at least one primary cutting perpendicular to the plane of said primary superposition so as to make available a connection zone ZC at the anode hereinafter anode connection area and is carried at least one primary perpendicularly to the plane of said primary cutting superposition so as to make available a connection zone ZC at the cathode following cathodic connection area. Advantageously, there is provided the primary cuts at opposite edges of said primary overlay. In a first embodiment, the edges of two adjacent sheets of the primary superposition comprising an alternating succession of cathode sheet and anode sheet are straight edges, the edge of a first sheet forming the protruding region RS then that the edge of a second sheet forming the recessed region RR. In a second embodiment, is carried out in the edge of a first sheet of the primary superposition comprising an alternating succession of cathode sheet and anode sheet, the first notches 50, 50 ', 50 ", 50"' having a first or large cross section, the wall of said first indentations constituting said recessed region RR, and is carried in a second adjacent sheet, the second notches having a second or small section, smaller than the first section, the wall of said second notches 50, 50 ', 50 ", 50"' constituting said protruding region RS. Advantageously, the cathode sheet and the anode sheet, have recesses 50, 50 ', 50 ", 50"' in a circle. Advantageously, there is provided, in a first sheet, the first openings having a first or large cross section, the wall of said ports constituting said recessed region RR, is carried out in a second adjacent sheet, the second openings having a second or smaller section, lower than the first section, the wall of said ports constituting said protruding region RS, it fills the inside of said ports by means of the encapsulation system or one of its variants and producing at least one secondary cut, preferably each secondary cutting , inside said first and second orifices, so that the ZC connection regions are formed adjacent the walls having the small cross-section and the overlap zones are formed near the walls having the large cross section. Advantageously is carried out in two adjacent sheets, first and second slots, mutually offset in the direction perpendicular to the plane of said sheets, filling the internal volume of said slots by means of the encapsulation system is carried at least one secondary cut, preferably each secondary cutting inside said slots, so that the connecting regions are formed adjacent the walls of a first slot and the overlap zones are formed near the walls of a second slot. Advantageously, after step (c), connects the connection zones ZC anode and cathode electrically together by a thin film deposition of an electron-conductive and wherein the deposition is performed by ALD 41, 41 '. Advantageously there is provided terminations 40, 40 anodic and cathodic sections by metallising precoated with a thin layer of an electronically conducting. Advantageously, after step (c), connects the areas of anode connection and cathode electrically together by a termination system comprising successively: o a first electronically conducting layer, preferably metallic, optional, preferably deposited by ALD 41, 41 ', o a second layer 42, 42' epoxy resin filled with silver, deposited on the first electronically conducting layer, and o a third layer 43, 43 'based on tin deposited on the second layer. In another embodiment, after step (c), connects the areas of anode connection and cathode electrically together by a termination system comprising successively: o a first electronically conducting layer, preferably a metal, optional, preferably deposited by ALD (41) o a second layer (42) epoxy resin filled with silver, deposited on the first electronically conducting layer, and o a third layer (43a) based on nickel deposited on the second layer, o a fourth layer (43b) based on tin or copper deposited on the third layer. Advantageously, the leaves have significantly larger dimensions than those of the final battery, characterized in that one performs at least one other tertiary said cutting, in a middle portion of said sheets. Advantageously, said electrically insulating material is selected from organic polymers or inorganic materials nonconductive having barrier properties with respect to water. Advantageously, said electrically insulating material is selected from Al 2 0 3 , Si0 2 , SiO y N x , and epoxy resins. Advantageously, the second covering layer comprises parylene N. Advantageously, the thickness of the first covering film is less than 200 nm, preferably between 5 nm and 200 nm, and even more preferably about 50 nm and the thickness of the second covering layer is between 1 μηη and 50 μηη, preferably from about 10 μηη. Advantageously, the thickness of the third covering film is between 1 and 50 μηη μηη, preferably less than 10 μηη, preferably less than 5 μηη and even more preferably from about 2 μηη. Advantageously, the layer of anode material is made from a material selected from: (i) the tin oxynitride (typical formula SnO x N y ); (ii) the lithium iron phosphate (formula typical LiFeP0 4 ); (iii) mixed oxynitrides of silicon and tin (typical formula Si a Sn b O y N z with a> 0, b> 0, a + b <2, 0 0, b> 0, a + b <2, 0 0, b> 0, a + b> 0, a + b <2, 0 0, b> 0, a + b <2, 0 0, b> 0, a + b <2, 0 0, b> 0, a + b <2, 0 0, b> 0, a + b> 0, a + b <2, 0 0, b> 0, a + b <2, 0

Documents

Application Documents

# Name Date
1 201917053294.pdf 2019-12-21
2 201917053294-TRANSLATIOIN OF PRIOIRTY DOCUMENTS ETC. [21-12-2019(online)].pdf 2019-12-21
3 201917053294-STATEMENT OF UNDERTAKING (FORM 3) [21-12-2019(online)].pdf 2019-12-21
4 201917053294-FORM 1 [21-12-2019(online)].pdf 2019-12-21
5 201917053294-DRAWINGS [21-12-2019(online)].pdf 2019-12-21
6 201917053294-DECLARATION OF INVENTORSHIP (FORM 5) [21-12-2019(online)].pdf 2019-12-21
7 201917053294-COMPLETE SPECIFICATION [21-12-2019(online)].pdf 2019-12-21
8 201917053294-Proof of Right [01-02-2020(online)].pdf 2020-02-01
9 201917053294-FORM-26 [01-02-2020(online)].pdf 2020-02-01
10 201917053294-FORM 3 [01-02-2020(online)].pdf 2020-02-01
11 201917053294-FORM 18 [09-04-2021(online)].pdf 2021-04-09
12 201917053294-Certified Copy of Priority Document [28-06-2021(online)].pdf 2021-06-28
13 201917053294-certified copy of translation [28-07-2021(online)].pdf 2021-07-28
14 201917053294-OTHERS [14-10-2021(online)].pdf 2021-10-14
15 201917053294-FER_SER_REPLY [14-10-2021(online)].pdf 2021-10-14
16 201917053294-CLAIMS [14-10-2021(online)].pdf 2021-10-14
17 201917053294-FER.pdf 2021-10-18
18 201917053294-PatentCertificate23-11-2021.pdf 2021-11-23
19 201917053294-RELEVANT DOCUMENTS [04-09-2023(online)].pdf 2023-09-04

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