Method of forming button-type battery lithium electrodes

• US 5,480,462 A
• Filed: 07/06/1994
• Issued: 01/02/1996
• Est. Priority Date: 03/02/1994
• Status: Expired due to Term

• Current Assignee: Round Rock Research LLC
• Original Assignee: Micron Communications, Inc. (Micron Technology, Inc.)
• Inventors: Tuttle, Mark E.
• Primary Examiner(s): Maples, John S.
• Application Number:
  US08/271,012
• Time in Patent Office: 545 Days
• Field of Search: 29/623.5, 427/272, 427/282, 427/250
• US Class Current: 29/623.5
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/0402 Methods of deposition of the material
• CPC Class Codes: H01M 4/0421 involving vapour deposition
• CPC Class Codes: H01M 4/0435 Rolling or calendering
• CPC Class Codes: H01M 4/0483 by methods including the handling of a melt H01M4/0438, take precedence
• CPC Class Codes: H01M 50/109 of button or coin shape
• CPC Class Codes: H01M 50/147 Lids or covers
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: Y10T 29/49112 including laminating of indefinite length material
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

A method of forming a button-type lithium electrode includes: a) masking an electrically conductive sheet with a material to which elemental lithium will not appreciably adhere to define a masked portion and an unmasked portion, the unmasked portion being in the shape of the desired electrode being formed; c) applying molten lithium to the masked sheet to cause elemental lithium to adhere to the unmasked portion but not appreciably adhere to the masked portion; alternately, directing a lithium stream onto the sheet; d) solidifying the lithium on the unmasked portion to in situ form a lithium electrode; and e) after solidifying, removing the masking material from the masked portion of the sheet. An alternate method includes: a) providing a release liner sheet having elemental lithium adhered thereto in the form of a series of discrete patterns having a size and shape of the lithium electrodes being formed; b) providing an electrically conductive sheet having an exposed surface which is divisible into a plurality of areas; c) laminating the release liner sheet with the conductive sheet to adhere the series of discrete elemental lithium patterns onto the respective sheet areas; d) pulling the release liner sheet from the conductive sheet and discrete lithium patterns, leaving the discrete lithium patterns adhering to the conductive sheet; and e) cutting and forming a plurality of discrete battery terminal housing members from the areas of the sheet, with each of the discrete battery terminal housings bearing one of the discrete lithium patterns.

Claims

1. A method of forming a button-type lithium electrode comprising the following steps:

providing an electrically conductive sheet having an exposed surface, the electrically conductive sheet being comprised of a material to which elemental lithium will adhere;

masking the electrically conductive sheet with a material to which elemental lithium will not appreciably adhere, the masking defining a masked portion and an unmasked portion, the unmasked portion of the conductive sheet having a cross-sectional size and shape of the desired electrode being formed;

applying molten lithium to the masked electrically conductive sheet to cause elemental lithium to adhere to the unmasked portion but not appreciably adhere to the masked portion;

solidifying the elemental lithium on the unmasked portion to in situ form a lithium electrode on the unmasked portion; and

after solidifying, removing the masking material from the masked portion of the conductive sheet.

2. The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the masking and applying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion.

3. The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the masking and applying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion.

4. The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to the masking and applying steps, the method further comprising after the solidifying step:

cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.

5. The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is at a temperature below the melting point of lithium immediately prior to the applying step.

6. The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the masking and applying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion;

and

wherein the electrically conductive sheet is at a temperature below the melting point of lithium immediately prior to the applying step.

7. The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the masking and applying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion;

and

wherein the electrically conductive sheet is at a temperature below the melting point of lithium immediately prior to the applying step.

8. The method of forming a button-type lithium electrode of claim 1 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to the masking and applying steps;

wherein the electrically conductive sheet is at a temperature below the melting point of lithium immediately prior to the applying step, and the method further comprising after the solidifying step;

cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.

9. A method of forming a button-type lithium electrode comprising the following steps:

providing an electrically conductive sheet having an exposed surface, the electrically conductive sheet being comprised of a material to which elemental lithium will adhere;

masking the electrically conductive sheet with a material to which elemental lithium will not appreciably adhere, the masking defining a masked portion and an unmasked portion, the unmasked portion of the conductive sheet having a cross-sectional size and shape of the desired electrode being formed;

providing and directing a lithium stream onto the electrically conductive sheet to cause elemental lithium to adhere to the unmasked portion but not appreciably adhere to the masked portion; and

solidifying the lithium stream on the unmasked portion to in situ form a lithium electrode.

10. The method of forming a button-type lithium electrode of claim 9 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion.

11. The method of forming a button-type lithium electrode of claim 9 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion.

12. The method of forming a button-type lithium electrode of claim 9 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to directing and solidifying steps, the method further comprising after the solidifying step:

cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.

13. The method of forming a button-type battery lithium electrode of claim 9 wherein the lithium stream is provided and directed in the form of a liquid stream.

14. The method of forming a button-type lithium electrode of claim 13 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion.

15. The method of forming a button-type lithium electrode of claim 13 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion.

16. The method of forming a button-type lithium electrode of claim 13 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to directing and solidifying steps, the method further comprising after the solidifying step:

cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.

17. The method of forming a button-type battery lithium electrode of claim 9 wherein the lithium stream is provided and directed in the form of a vaporized stream.

18. The method of forming a button-type lithium electrode of claim 17 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having a peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion comprising the peripheral portion, the unmasked portion comprising the central portion.

19. The method of forming a button-type lithium electrode of claim 17 wherein the electrically conductive sheet is provided in the form of a pre-formed electrically conductive terminal housing member prior to the directing and solidifying steps, the preformed terminal housing member defining an electrode receptacle having an internal peripheral portion and a central portion, the peripheral portion angling away from the central portion at a peripheral angle to define a central portion cross-sectional shape and periphery, the masked portion covering all of the internal peripheral portion, the unmasked portion at least exposing all of the central portion.

20. The method of forming a button-type lithium electrode of claim 17 wherein the electrically conductive sheet is not pre-formed into a terminal housing member shape prior to directing and solidifying steps, the method further comprising after the solidifying step:

cutting and forming a discrete battery terminal housing member from the electrically conductive sheet.