Solid-state laminate electrode assemblies and methods of making

Patent metadata

Field	Value
Publication number	US-2020395633-A1
Application number	US-202015929959-A
Country	US
Kind code	A1
Filing date	May 29, 2020
Priority date	May 10, 2016
Publication date	Dec 17, 2020
Grant date	—

Abstract

Solid-state laminate electrode assemblies and various methods for making the solid-state laminate electrode assemblies involve a lithium metal layer reactively bonded to a lithium ion conducting sulfide glass layer. During manufacture, highly reactive surfaces of the lithium metal layer and the lithium ion conducting sulfide glass layer are maintained in its substantially unpassivated state until they have been reactively bonded.

First claim

1 - 14 . (canceled)

15 . A lithium metal laminate structure, the laminate comprising:
i) a lithium metal layer having a first and second major surface, wherein the first major surface is substantially unpassivated; and ii) a fluid protective material layer that removably covers and protects the lithium first major surface in direct contact.

16 . The lithium metal laminate structure of claim 15 , wherein the substantially unpassivated lithium metal surface is stable.

17 . The lithium metal laminate structure of claim 15 , wherein the protective material layer is a liquid phase dry hydrocarbon liquid.

18 . An inorganic solid electrolyte laminate structure, the laminate comprising:
i) a lithium ion conducting sulfide glass layer having a first and second major surface; and ii) a fluid protective material layer that removably covers and protects the sulfide glass first major surface.

19 . The solid electrolyte laminate structure of claim 18 , wherein the protective material layer is a dry liquid phase hydrocarbon liquid.

20 - 22 . (canceled)

23 . A method for making a battery cell, the method comprising making a solid-state electrode assembly, comprising the steps of
i) providing a lithium metal laminate structure, the lithium metal laminate structure comprising:
a. a lithium metal layer having a first major surface that is substantially unpassivated; and
b. a first fluid inert protective material layer that removably covers the lithium metal layer first major surface, the first inert protective material layer in direct contact with the lithium metal layer first major surface;
ii) providing an inorganic solid electrolyte laminate structure, the electrolyte laminate structure comprising:
a. an inorganic lithium ion conducting sulfide glass layer having a first major surface and an opposing second major surface; and
b. a second fluid inert protective material layer that removably covers the sulfide glass layer first major surface, the second inert protective material layer in direct contact with the sulfide glass layer;
iii) removing the first inert protective material layer from the lithium metal layer first major surface; iv) removing the second inert protective material layer from the sulfide glass layer first major surface; v) reactively bonding the sulfide glass layer with the lithium metal layer via their first major surfaces; and wherein the reactive bond provides an interface between the sulfide glass layer and the lithium metal layer defined by a continuous solid electrolyte interphase; and placing a positive electrode layer adjacent to the second major surface of the sulfide glass layer.

24 . The method of claim 23 , wherein the second fluid inert protective material layer on the sulfide glass layer first major surface is a layer of a second dry hydrocarbon liquid, and the first fluid inert protective material layer on the substantially unpassivated lithium metal layer first major surface is a layer of a first dry hydrocarbon liquid.

25 . The method of claim 24 , wherein the first dry hydrocarbon liquid on the lithium metal layer surface is removed substantially immediately prior to the reactive bonding.

26 . The method of claim 25 , wherein the removal of the first hydrocarbon liquid is accelerated by the application of one or more of heat, vacuum suction, blowing a jet of dry Ar or He, and blowing a jet of high vapor pressure protective liquid followed by vacuum suction.

27 . The method of claim 26 , further comprising cleaning the first major surface of the sulfide glass layer by ion etching under an argon plasma, wherein the cleaning is performed after the liquid phase layer of the second dry hydrocarbon liquid has been removed.

28 . The method of claim 25 , wherein the first liquid phase protective fluid is a hydrocarbon liquid comprising not greater than 0.1 ppm of moisture.

29 . The method of claim 25 , wherein the second dry hydrocarbon liquid on the sulfide glass layer is removed substantially immediately prior to the reactive bonding.

30 . The method of claim 29 , wherein the second liquid phase protective fluid is a hydrocarbon liquid comprising not greater than 0.1 ppm of moisture.

31 . The lithium metal laminate structure of claim 17 , wherein the liquid phase protective fluid is a hydrocarbon liquid comprising not greater than 0.1 ppm of moisture.

32 . The solid electrolyte laminate structure of claim 19 , wherein the liquid phase protective fluid is a hydrocarbon liquid comprising not greater than 0.1 ppm of moisture.

Assignees

• Polyplus Battery Co Inc

Inventors

• Visco Steven J
• Nimon Vitaliy
• Wogan Ian
• Nimon Yevgeniy S
• De Jonghe Lutgard C
• Katz Bruce D

Classifications

• H01M4/0407

  by coating on an electrolyte layer · CPC title

• H01M10/052

  Li-accumulators · CPC title

• H01M10/0562

  Solid materials · CPC title

• H01M4/382

  Lithium (H01M4/405 takes precedence) · CPC title

• H01M2300/0068

  inorganic · CPC title