Layered arrangements of lithium electrodes
AssigneePolyPlus Battery Company
InventorsMay-Ying Chu, Steven J. Visco, Lutgard C. DeJonghe
Life of this patent
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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.
Claims59
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 foil bonding layer disposed on the barrier layer, the foil bonding layer capable of forming a bond with the active metal;
- and
- (b) bonding active metal to the foil bonding layer.
A method of fabricating an active metal electrode, the method comprising:
- (a) providing a barrier layer laminate comprising a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of active metal;
- (b) attaching a foil bonding layer to the barrier layer of the barrier layer laminate, wherein the foil bonding layer comprises a material capable of forming a bond with active metal;
- and
- (c) bonding active metal to the foil bonding 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 the active metal, and
- (iii) a foil bonding layer disposed on the barrier layer, wherein the foil bonding layer comprises a material capable of forming a bond with the active metal.
An active metal electrode capable of serving as a negative electrode in a battery, the active metal electrode comprising:
- (i) a barrier layer forming a substantially impervious layer which is conductive to ions of the active metal;
- (ii) a first active metal layer having a first side disposed on to the barrier layer;
- (iii) a bonding layer disposed on a second side, opposite the first side, of the active metal layer, the bonding layer material being capable of forming a bond with the active metal;
- and
- (iv) a second active metal layer disposed on the bonding layer, wherein the bonding layer is sandwiched between the first and second active metal layers.
A method of fabricating an active metal electrode, the method comprising:
- (a) providing a barrier layer laminate comprising a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of the active metal;
- (b) providing an active metal laminate comprising at least one active metal layer and a bonding layer affixed to one another, wherein the bonding layer is capable of forming a bond with the active metal;
- and
- (c) bonding at least the active metal laminate and the barrier layer laminate to form an electrode structure in which (i) the bonding layer is sandwiched between two separate active metal layers, at least one of which was provided in the active metal laminate, and (ii) one of the two separate active metal layers is affixed to the barrier layer provided in the barrier layer laminate.
A method of fabricating an active metal electrode including a barrier layer forming a substantially impervious layer which is conductive to ions of the active metal, the method comprising:
- (a) forming the barrier layer on a metal bonding layer to create a barrier layer laminate, the bonding layer being capable of forming a bond with the active metal;
- and
- (b) bonding the barrier layer laminate to a layer of active metal by affixing the active metal layer to the bonding layer of the barrier layer laminate.
Dependencies are inferred from the claim text.