Encapsulated lithium alloy electrodes having barrier layers
AssigneePolyPlus Battery Company
InventorsMay-Ying Chu, Steven J. Visco, Lutgard C. DeJonghe
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Abstract
A method employing a bonding layer is used to form active metal electrodes having barrier layers. Active metals such as lithium are highly reactive in ambient conditions. The method involves fabricating a lithium electrode or other active metal electrode without depositing the barrier layer on a layer of metal. Rather a smooth barrier layer is formed on a smooth substrate such as a web carrier or polymeric electrolyte. A bonding or alloying layer is formed on top of the barrier layer. Lithium or other active material is then attached to the bonding layer to form the active metal electrode. A current collector may also be attached to the lithium or active metal during the process.
Claims32
A method of fabricating an active metal electrode, the method comprising:
- (a) providing a barrier layer laminate comprising (i) a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of the active metal, and (ii) a bonding layer disposed on the barrier layer, the material of the bonding layer being capable of forming a bond with the active metal;
- and
- (b) bonding active metal to the barrier layer.
A barrier layer laminate for use in fabricating an active metal electrode, the barrier layer laminate comprising:
- (i) a substantially smooth and flat substrate;
- (ii) a barrier layer disposed on the substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of an active metal, and
- (iii) a bonding layer, comprised of aluminum or an aluminum alloy disposed on the barrier layer, the bonding layer being capable of forming a bond with the active metal.
A method of fabricating an active metal electrode, the method comprising:
- (a) providing a barrier layer laminate comprising a polymeric barrier layer disposed on a substrate, the polymeric barrier layer forming a substantially impervious polymeric layer which is conductive to ions of an active metal;
- and
- (b) bonding the active metal to the barrier layer by a chemical reaction of the active metal with a surface of the polymeric barrier layer.
Dependencies are inferred from the claim text.