Method for forming encapsulated lithium electrodes having glass protective layers

• US 6,432,584 B1
• Filed: 10/02/2000
• Issued: 08/13/2002
• Est. Priority Date: 05/01/1998
• Status: Expired due to Term

• Current Assignee: PolyPlus Battery Company
• Original Assignee: PolyPlus Battery Company
• Inventors: Visco, Steven J., Tsang, Floris Y.
• Primary Examiner(s): CHANEY, CAROL DIANE
• Application Number:
  US09/678,063
• Time in Patent Office: 680 Days
• Field of Search: 429/231.95, 429/218.1, 429/232, 429/246, 429/248
• US Class Current: 429/231.95
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 2300/0085 Immobilising or gelification of electrolyte
• 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 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0407 by coating on an electrolyte layer
• CPC Class Codes: H01M 4/0423 Physical vapour deposition
• CPC Class Codes: H01M 4/0428 Chemical vapour deposition
• CPC Class Codes: H01M 4/13 Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• CPC Class Codes: H01M 4/139 Processes of manufacture
• CPC Class Codes: H01M 6/185 with oxides, hydroxides or oxysalts as solid electrolytes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

A method for fabricating an active metal electrode involves depositing lithium or other active metal electrode on a protective layer. The protective layer is a glassy or amorphous material that conducts ions of the active metal. It may be deposited on a releasable web carrier or other substrate such as polymer electrolyte layer. Lithium is then deposited on the protective layer. Finally, a current collector is attached to the lithium.

Claims

1. A stand-alone active metal negative electrode that is not affixed to a positive electrode, wherein the negative electrode is formed by the following method:

(a) forming a glassy or amorphous protective layer on a substrate, the protective layer forming a substantially impervious layer which is conductive to ions of an active metal;

(b) depositing a first active metal layer on the protective layer; and

(c) providing a current collector on the first active metal layer to form the stand-alone active metal electrode.

2. A battery comprising the active metal electrode of claim 1.

3. The battery of claim 2, wherein the battery is a lithium-sulfur battery.

4. A stand-alone partially fabricated battery cell that does not include a positive electrode, consisting essentially of:

a current collector;

a glassy or amorphous protective layer forming a substantially impervious layer which is a single ion conductor conductive to ions of an active metal;

an active metal layer provided between the current collector and the protective layer; and

a gel or solid electrolyte provided on the protective layer opposite the active metal layer.

5. The partially fabricated battery cell of claim 4, wherein the current collector is a layer of metal.

6. The partially fabricated battery cell of claim 5, wherein the metal is selected from the group consisting of copper, nickel, stainless steel, and zinc.

7. The partially fabricated battery cell of claim 4, wherein the current collector is a metallized plastic sheet.

8. The partially fabricated battery cell of claim 4, wherein the protective layer is conductive to lithium ions.

9. The partially fabricated battery cell of claim 4, wherein the protective layer includes at least one of a lithium silicate, a lithium borate, a lithium aluminate, a lithium phosphate, a lithium phosphorus oxynitride, a lithium silicosulfide, a lithium borosulfide, a lithium aluminosulfide, and a lithium phosphosulfide.

10. The partially fabricated battery cell of claim 4, wherein the protective layer has a thickness of between about 50 angstroms and 5 micrometers.

11. The partially fabricated battery cell of claim 10, wherein the protective layer has a thickness of between about 500 angstroms and 2000 angstroms.

12. The partially fabricated battery cell of claim 4, wherein the protective layer has a conductivity of between about 10⁻

8 and about 10<sup>−

2</sup> (ohm-cm)<sup>−

1</sup>.

13. The partially fabricated battery cell of claim 4, wherein the gel or solid electrolyte comprises a material selected from the group consisting of polyethers, polyimines, polythioethers, polyphosphazenes, and polymer blends, mixtures, and copolymers thereof.

14. The partially fabricated battery cell of claim 4, wherein the gel or solid electrolyte comprises a polyalkylene oxide.

15. A battery cell comprising the partially fabricated battery cell of claim 4.

16. The battery cell of claim 15, wherein the battery cell is a lithium-sulfur battery cell.