Thin-film batteries with polymer and LiPON electrolyte layers and method
First Claim
1. A battery cell having a negative electrode, a positive electrode, and an electrolyte structure, wherein the negative electrode includes a first LiPON layer covering at least a portion of the negative electrode and having randomly spaced defects;
- the positive electrode includes a cathode material and a second LiPON layer covering at least a portion of the positive electrode and having randomly spaced defects; and
the electrolyte structure includes a polymer electrolyte material sandwiched between the LiPON layer of the negative electrode and the LiPON layer of the positive electrode, wherein the randomly spaced defects in the first and second LiPON layers are at least partially filled by the polymer electrolyte material and wherein the polymer electrolyte layer fixes defects in at least one of the LiPON layers, wherein the polymer electrolyte layer includes a gel.
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Accused Products
Abstract
A method and apparatus for making thin-film batteries having composite multi-layered electrolytes with soft electrolyte between hard electrolyte covering the negative and/or positive electrode, and the resulting batteries. In some embodiments, foil-core cathode sheets each having a cathode material (e.g., LiCoO2) covered by a hard electrolyte on both sides, and foil-core anode sheets having an anode material (e.g., lithium metal) covered by a hard electrolyte on both sides, are laminated using a soft (e.g., polymer gel) electrolyte sandwiched between alternating cathode and anode sheets. A hard glass-like electrolyte layer obtains a smooth hard positive-electrode lithium-metal layer upon charging, but when very thin, have randomly spaced pinholes/defects. When the hard layers are formed on both the positive and negative electrodes, one electrode'"'"'s dendrite-short-causing defects on are not aligned with the other electrode'"'"'s defects. The soft electrolyte layer both conducts ions across the gap between hard electrolyte layers and fills pinholes.
289 Citations
24 Claims
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1. A battery cell having a negative electrode, a positive electrode, and an electrolyte structure, wherein the negative electrode includes a first LiPON layer covering at least a portion of the negative electrode and having randomly spaced defects;
- the positive electrode includes a cathode material and a second LiPON layer covering at least a portion of the positive electrode and having randomly spaced defects; and
the electrolyte structure includes a polymer electrolyte material sandwiched between the LiPON layer of the negative electrode and the LiPON layer of the positive electrode, wherein the randomly spaced defects in the first and second LiPON layers are at least partially filled by the polymer electrolyte material and wherein the polymer electrolyte layer fixes defects in at least one of the LiPON layers, wherein the polymer electrolyte layer includes a gel. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
- the positive electrode includes a cathode material and a second LiPON layer covering at least a portion of the positive electrode and having randomly spaced defects; and
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17. A battery cell comprising:
- a first sheet that includes a first LiPON layer covering a first face of the first sheet, the first LiPON layer having defects therein;
a second sheet that includes a cathode material that includes lithium and a second LiPON layer covering the cathode material on a second face of the second sheet, the second LiPON layer having defects therein; and
means for at least partially filling and fixing the defects of the first and second LiPON layers and for passing lithium ions between the first LiPON layer and the second LiPON layer to form a first battery cell, wherein the means for at least partially filling and fixing defect of the first and second LiPON layers includes a polymer electrolyte layer including a gel. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24)
- a first sheet that includes a first LiPON layer covering a first face of the first sheet, the first LiPON layer having defects therein;
Specification