US 7,070,632 B1 · Electrochemical device separator structures with barrier layer on non-swelling membrane

Abstract

Disclosed are electrochemical device separator structures which include a substantially impervious active metal ion conducting barrier layer material, such as an ion conducting glass, is formed on an active metal ion conducting membrane in which elongation due to swelling on contact with liquid electrolyte is constrained in at least two of three orthogonal dimensions of the membrane. The non-swelling character of the membrane prevents elongation in the x-y (or lateral, relative to the layers of the composite) orthogonal dimensions of the membrane when it is contacted with liquid electrolyte that would otherwise cause the barrier layer to rupture. Substantial swelling of the membrane, if any, is limited to the z (or vertical, relative to the layers of the composite) dimension.

Claims23

Dependent claims

A method of fabricating a battery cell structure, comprising:

forming a barrier layer on a substrate layer of a membrane material, the barrier layer being substantially impervious to liquid electrolyte, the membrane material characterized in that elongation due to swelling on contact with liquid electrolyte is constrained in at least two of three orthogonal dimensions of the material, the membrane material being selected from the group consisting of a fiber-reinforced polymer and a polymer reinforced with a punched, woven or mesh material;
forming an active metal negative electrode on the barrier layer;
and
assembling the negative electrode/barrier/membrane laminate structure with a cathode and a liquid electrolyte in a cell container;
wherein said membrane material layer and said barrier layer are conductive to ions of an active metal.

2 more elements

Dependencies are inferred from the claim text.

Electrochemical device separator structures with barrier layer on non-swelling membrane

Life of this patent

Electrochemical device separator structures with barrier layer on non-swelling membrane

Life of this patent

Abstract

Claims23