Electrode protection using a composite comprising an electrolyte-inhibiting ion conductor

An electrochemical cell, comprising:

• a first electrode comprising lithium as an electroactive material;
• a second electrode;
• and
• a composite positioned between the first and second electrodes, the composite comprising:
• a separator comprising pores having an average pore size, wherein the separator has a bulk electronic resistivity of at least about 104 Ohm-meters;
• and
• an ion conductor layer bonded to the separator,
• wherein the separator and the ion conductor layer have a strength of adhesion that passes a tape test according to standard ASTM D3359-02,
• wherein the ion conductor layer has a lithium-ion conductivity of at least 10−6 S/cm and less than 20 S/cm, and
• wherein the ion conductor layer comprises a lithium oxysulfide.

A process of making an electrochemical cell, comprising the following steps:

• providing a separator comprising pores, wherein the separator has a bulk electronic resistivity of at least about 104 Ohm-meters;
• bonding a solid ion conductor layer to the separator to form a composite, wherein the separator and the ion conductor layer have a strength of adhesion that passes a tape test according to standard ASTM D3359-02, wherein the solid ion conductor layer comprises a lithium oxysulfide, and wherein the solid ion conductor layer is substantially formed of a non-polymeric material;
• and
• assembling the electrochemical cell.