Solid-state laminate electrode assemblies and battery cells thereof

Patent metadata

Field	Value
Publication number	US-2025006984-A1
Application number	US-202418645270-A
Country	US
Kind code	A1
Filing date	Apr 24, 2024
Priority date	May 10, 2016
Publication date	Jan 2, 2025
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. An intermediary solid electrolyte structure has a Li ion conducting solid electrolyte layer covered with a thin as-deposited lithium phosphorus nitride film. A surface protected solid electrolyte having a solid electrolyte layer having a first major surface that is covered by a composite protective film, the composite protective film having a lithium phosphorus material component and a phosphorus nitride material component. A physical vapor deposition target for the deposition of a composite protective film, the target having a compacted composite material target having a mosaic structure.

First claim

1 - 21 . (canceled)

22 . A standalone electrochemical material layer structure having a wet-decal architecture, the structure comprising a battery active material layer surface, a solid material release layer, and a protective inert liquid layer sandwiched between the active material layer surface and the release layer.

23 . The standalone electrochemical material layer structure of claim 22 wherein the inert liquid layer encapsulates the surface of the battery active material layer.

24 . The standalone electrochemical material layer structure of claim 23 wherein the inert liquid layer completely wets out the battery active material layer surface, leading to a liquid bridge between the layers, and a wet adhesive force that assists in maintaining the release layer on the battery active material layer during handling and processing.

25 . The standalone electrochemical material layer structure of claim 24 wherein the degree of wetting is sufficient to prevent the solid release layer from touching the battery active material.

26 . The standalone electrochemical material layer structure of claim 25 wherein the thickness of the protective inert liquid layer is not greater than 50 um.

27 . The standalone electrochemical material layer structure of claim 22 wherein the battery active material layer is a solid electrolyte layer.

28 . The standalone electrochemical material layer structure of claim 27 wherein solid electrolyte layer is an ion conducting sulfide glass layer.

29 . The standalone electrochemical material layer structure of claim 26 wherein the battery active material layer is a Li metal layer.

30 . The standalone electrochemical material layer structure of claim 29 , and further comprising a nanofilm encapsulated solid electrolyte layer.

31 . The standalone electrochemical material layer structure of claim 30 , wherein the solid electrolyte layer is a lithium ion conducting sulfide glass.

32 . The standalone electrochemical material structure of claim 30 , and further comprising a solid electrolyte layer having a nitrogen rich Li—P—N film substantially devoid of oxygen.

33 . The standalone electrochemical material layer structure of claim 32 , wherein the solid electrolyte layer is a lithium ion conducting sulfide glass.

34 . The standalone electrochemical material structure of claim 30 , and further comprising a solid electrolyte layer having a surface protective metal layer.

35 . The standalone electrochemical material layer structure of claim 34 , wherein the solid electrolyte layer is a lithium ion conducting sulfide glass.

36 . A method of making a battery, comprising:
providing a standalone electrochemical material layer structure having a wet-decal architecture, the structure comprising a battery active material layer surface, a solid material release layer, and a protective inert liquid layer sandwiched between the active material layer surface and the release layer; and providing a cathode layer adjacent to the standalone electrochemical material layer structure.

Assignees

• Polyplus Battery Co Inc

Inventors

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

Classifications

• H01M10/052

  Li-accumulators · CPC title

• H01M50/403

  Manufacturing processes of separators, membranes or diaphragms · CPC title

• H01M50/457

  comprising three or more layers · CPC title

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M50/437

  Glass · CPC title