US6413285B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Layered arrangements of lithium electrodes
Assignee: Polyplus Battery Co Inc
•
Filing: 2000-08-16
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Granted: 2002-07-02
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Expires: 2020-08-16
Abstract
Abstract A method employing a bonding layer is used to form active metal electrodes having barrier layers. Active metals such as lithium are highly reactive in ambient conditions. The method involves fabricating a lithium electrode or other active metal electrode without depositing the barrier layer on a layer of metal. Rather a smooth barrier layer is formed on a smooth substrate such as a web carrier or polymeric electrolyte. A bonding or alloying layer is formed on top of the barrier layer. Lithium or other active material is then attached to the bonding layer to form the active metal electrode. A current collector may also be attached to the lithium or active metal during the process.
Inventors
- 👤 May-Ying Chu
- 👤 Steven J. Visco
- 👤 Lutgard C. DeJonghe
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 09:05
CPC Classifications
H; H01; H01M; H01M4/00; H01M4/02; H01M4/13; H01M4/139; H01M4/1395; H01M4/04; H01M4/0402; H01M4/0421; H01M4/0428; H01M4/0404; H01M4/0407; H01M4/0411; H01M4/0423; H01M4/0426; H01M4/043; H01M4/049; H01M4/0495; H01M4/64; H01M4/66; H01M10/00; H01M10/05; H01M6/00; H01M6/40; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49108; Y10T29/49114
Claims Analysis
Total Claims: 65
Claim 1
Independent Claim
77 words
A method of fabricating an active metal electrode, the method comprising: (a) providing a barrier layer laminate comprising (i) a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of the active metal, and (ii) a foil bonding layer disposed on the barrier layer, the foil bonding layer capable of forming a bond with the active metal; and (b) bonding active metal to the foil bonding layer.
Claim 2
Independent Claim
77 words
A method of fabricating an active metal electrode, the method comprising: (a) providing a barrier layer laminate comprising (i) a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of the active metal, and (ii) a foil bonding layer disposed on the barrier layer, the foil bonding layer capable of forming a bond with the active metal; and (b) bonding active metal to the foil bonding layer.
Claim 3
Dependent Claim
21 words
The method of claim 1 , wherein the substrate on which the barrier layer is disposed is a releasable web carrier.
Claim 4
Dependent Claim
34 words
The method of claim 2 , wherein the releasable web carrier includes a release layer of copper, tin, zinc, aluminum, iron, a polymeric material, or combination thereof on which the barrier layer is disposed.
Claim 5
Dependent Claim
23 words
The method of claim 1 , wherein the substrate on which the barrier layer is disposed is a solid-state or gel-state electrolyte separator.
Claim 6
Dependent Claim
21 words
The method of claim 1 , wherein the substrate on which the barrier layer is disposed is a polymeric electrolyte separator.
Claim 7
Dependent Claim
26 words
The method of claim 1 , further comprising forming the barrier layer on the substrate by a physical deposition process or a chemical vapor deposition process.
Claim 8
Dependent Claim
49 words
The method of claim 1 , wherein the barrier layer is a glass layer that 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.
Claim 9
Dependent Claim
15 words
The method of claim 1 , wherein the barrier layer comprises an organic polymeric material.
Claim 10
Dependent Claim
21 words
The method of claim 8 , wherein the organic polymeric material includes at least one of nitrogen atoms or phosphorus atoms.
Claim 11
Dependent Claim
25 words
The method of claim 1 , wherein the barrier layer is a glass layer having a thickness of between about 50 angstroms and 5 micrometers.
Claim 12
Dependent Claim
26 words
The method of claim 1 , wherein the barrier layer has an ionic conductivity of between about 10 −8 and about 10 −2 (ohm-cm) −1 .
Claim 13
Dependent Claim
19 words
The method of claim 1 , wherein the foil bonding layer is not substantially reactive with moisture and air.
Claim 14
Dependent Claim
37 words
The method of claim 1 , wherein the foil bonding layer is comprised of at least one of aluminum, an aluminum alloy, silicon, zinc, manganese, silver, antimony, magnesium, lead, tin, iron, titanium and alloys of such metals.
Claim 15
Dependent Claim
19 words
The method of claim 1 , wherein the foil bonding layer is comprised of aluminum or an aluminum alloy.
Claim 16
Dependent Claim
29 words
The method of claim 1 , wherein the foil bonding layer is an aluminum layer or aluminum alloy layer having a thickness between about 0.1 micrometers and 100 micrometers.
Claim 17
Dependent Claim
16 words
The method of claim 1 , further comprising attaching a current collector on the active metal.
Claim 18
Dependent Claim
17 words
The method of claim 1 , wherein the active metal is lithium or an alloy of lithium.
Claim 19
Dependent Claim
27 words
The method of claim 1 , wherein the active metal is lithium or an alloy of lithium and has a thickness of at least about 0.2 micrometers.
Claim 20
Dependent Claim
27 words
The method of claim 1 , wherein bonding active metal to the foil bonding layer comprises bonding a free standing lithium layer to the foil bonding layer.
Claim 21
Dependent Claim
35 words
The method of claim 1 , wherein bonding the active metal to the foil bonding layer comprises bonding a laminate of an active metal layer and a current collector layer to the foil bonding layer.
Claim 22
Dependent Claim
27 words
The method of claim 1 , wherein bonding the active metal to the foil bonding layer comprises pressing an active metal layer to the barrier layer laminate.
Claim 23
Dependent Claim
23 words
The method of claim 21 , wherein pressing the active metal layer to the barrier layer laminate is done in a hot press.
Claim 24
Dependent Claim
29 words
The method of claim 1 , wherein bonding the active metal to the foil bonding layer comprises evaporating or sputtering the active metal on to the barrier layer laminate.
Claim 25
Dependent Claim
19 words
An active metal electrode formed by the method of claim 1 , wherein the bonding layer is a metal.
Claim 26
Dependent Claim
11 words
A battery comprising the active metal electrode of claim 24 .
Claim 27
Dependent Claim
13 words
The battery of claim 25 , wherein the battery is a lithium-sulfur battery.
Claim 28
Dependent Claim
60 words
The method of claim 1 , wherein the barrier layer laminate further comprises an active metal layer that is disposed on a side of the foil bonding layer that is opposite the barrier layer, and wherein bonding the active metal to the foil bonding layer comprises bonding the active metal to the active metal layer of the barrier layer laminate.
Claim 29
Independent Claim
82 words
A method of fabricating an active metal electrode, the method comprising: (a) providing a barrier layer laminate comprising a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of active metal; (b) attaching a foil bonding layer to the barrier layer of the barrier layer laminate, wherein the foil bonding layer comprises a material capable of forming a bond with active metal; and (c) bonding active metal to the foil bonding layer.
Claim 30
Independent Claim
82 words
A method of fabricating an active metal electrode, the method comprising: (a) providing a barrier layer laminate comprising a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of active metal; (b) attaching a foil bonding layer to the barrier layer of the barrier layer laminate, wherein the foil bonding layer comprises a material capable of forming a bond with active metal; and (c) bonding active metal to the foil bonding layer.
Claim 31
Dependent Claim
77 words
A barrier layer laminate for use in fabricating an active metal electrode, the barrier layer laminate comprising: (i) a substantially smooth and flat substrate; (ii) a barrier layer disposed on the substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of the active metal, and (iii) a foil bonding layer disposed on the barrier layer, wherein the foil bonding layer comprises a material capable of forming a bond with the active metal.
Claim 32
Dependent Claim
77 words
A barrier layer laminate for use in fabricating an active metal electrode, the barrier layer laminate comprising: (i) a substantially smooth and flat substrate; (ii) a barrier layer disposed on the substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of the active metal, and (iii) a foil bonding layer disposed on the barrier layer, wherein the foil bonding layer comprises a material capable of forming a bond with the active metal.
Claim 33
Dependent Claim
23 words
The barrier layer laminate of claim 29 , wherein the substrate on which the barrier layer is disposed is a releasable web carrier.
Claim 34
Dependent Claim
23 words
The barrier layer laminate of claim 29 , wherein the substrate on which the barrier layer is disposed is a polymeric electrolyte separator.
Claim 35
Dependent Claim
33 words
The barrier layer laminate of claim 31 , wherein the polymeric electrolyte separator comprises a material selected from the group consisting of polyethers, polyimines, polythioethers, polyphosphazenes, and polymer blends, mixtures, and copolymers thereof.
Claim 36
Dependent Claim
17 words
The barrier layer laminate of claim 31 , wherein the polymeric electrolyte separator comprises a polyalkylene oxide.
Claim 37
Dependent Claim
46 words
The barrier layer laminate of claim 29 , wherein the barrier 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.
Claim 38
Dependent Claim
27 words
The barrier layer laminate of claim 29 , wherein the barrier layer is a glass layer having a thickness of between about 50 angstroms and 5 micrometers.
Claim 39
Dependent Claim
27 words
The barrier layer laminate of claim 29 , wherein the barrier layer is a glass and has a thickness of between about 500 angstroms and 2000 angstroms.
Claim 40
Dependent Claim
21 words
The barrier layer laminate of claim 29 , wherein the foil bonding layer is not substantially reactive with moisture and air.
Claim 41
Dependent Claim
39 words
The barrier layer laminate of claim 29 , wherein the foil bonding layer is comprised of at least one of aluminum, an aluminum alloy, silicon, zinc, manganese, silver, antimony, magnesium, lead, tin, iron, titanium and alloys of such metals.
Claim 42
Dependent Claim
21 words
The barrier layer laminate of claim 29 , wherein the foil bonding layer is comprised of aluminum or an aluminum alloy.
Claim 43
Dependent Claim
30 words
The barrier layer laminate of claim 29 , wherein the foil bonding layer is an aluminum or aluminum alloy layer having a thickness between about 0.1 micrometers and 100 micrometers.
Claim 44
Dependent Claim
19 words
The barrier layer laminate of claim 29 , wherein the active metal is lithium or an alloy of lithium.
Claim 45
Dependent Claim
24 words
An active metal electrode comprising an active metal layer bonded to the foil bonding layer of the barrier layer laminate of claim 29 .
Claim 46
Dependent Claim
11 words
A battery comprising the active metal electrode of claim 42 .
Claim 47
Dependent Claim
13 words
The battery of claim 43 , wherein the battery is a lithium-sulfur battery.
Claim 48
Dependent Claim
111 words
An active metal electrode capable of serving as a negative electrode in a battery, the active metal electrode comprising: (i) a barrier layer forming a substantially impervious layer which is conductive to ions of the active metal; (ii) a first active metal layer having a first side disposed on to the barrier layer; (iii) a bonding layer disposed on a second side, opposite the first side, of the active metal layer, the bonding layer material being capable of forming a bond with the active metal; and (iv) a second active metal layer disposed on the bonding layer, wherein the bonding layer is sandwiched between the first and second active metal layers.
Claim 49
Dependent Claim
111 words
An active metal electrode capable of serving as a negative electrode in a battery, the active metal electrode comprising: (i) a barrier layer forming a substantially impervious layer which is conductive to ions of the active metal; (ii) a first active metal layer having a first side disposed on to the barrier layer; (iii) a bonding layer disposed on a second side, opposite the first side, of the active metal layer, the bonding layer material being capable of forming a bond with the active metal; and (iv) a second active metal layer disposed on the bonding layer, wherein the bonding layer is sandwiched between the first and second active metal layers.
Claim 50
Dependent Claim
44 words
The active metal electrode of claim 45 , further comprising a substantially smooth and flat substrate disposed on a first side of the barrier layer, wherein the active metal layer is disposed on a second side, opposite the first side, of the barrier layer.
Claim 51
Dependent Claim
17 words
The active metal electrode of claim 45 , wherein the bonding layer is a foil bonding layer.
Claim 52
Independent Claim
144 words
A method of fabricating an active metal electrode, the method comprising: (a) providing a barrier layer laminate comprising a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of the active metal; (b) providing an active metal laminate comprising at least one active metal layer and a bonding layer affixed to one another, wherein the bonding layer is capable of forming a bond with the active metal; and (c) bonding at least the active metal laminate and the barrier layer laminate to form an electrode structure in which (i) the bonding layer is sandwiched between two separate active metal layers, at least one of which was provided in the active metal laminate, and (ii) one of the two separate active metal layers is affixed to the barrier layer provided in the barrier layer laminate.
Claim 53
Independent Claim
144 words
A method of fabricating an active metal electrode, the method comprising: (a) providing a barrier layer laminate comprising a barrier layer disposed on a substrate, the barrier layer forming a substantially impervious layer which is conductive to ions of the active metal; (b) providing an active metal laminate comprising at least one active metal layer and a bonding layer affixed to one another, wherein the bonding layer is capable of forming a bond with the active metal; and (c) bonding at least the active metal laminate and the barrier layer laminate to form an electrode structure in which (i) the bonding layer is sandwiched between two separate active metal layers, at least one of which was provided in the active metal laminate, and (ii) one of the two separate active metal layers is affixed to the barrier layer provided in the barrier layer laminate.
Claim 54
Dependent Claim
13 words
The method of claim 48 , wherein the bonding layer is a foil.
Claim 55
Dependent Claim
76 words
The method of claim 48 , wherein the active metal laminate consists essentially of the bonding layer and a single active metal layer, and wherein bonding at least the active metal laminate and the barrier layer laminate comprises (a) bonding a second active metal layer to the bonding layer of the active metal laminate and (b) bonding the barrier layer of the barrier layer laminate to the single active metal layer of the active metal laminate.
Claim 56
Dependent Claim
29 words
The method of claim 48 , wherein the barrier layer laminate further comprises a second active metal layer disposed on a side of the barrier layer opposite the substrate.
Claim 57
Dependent Claim
51 words
The method of claim 51 , wherein the active metal laminate comprises the bonding layer and a single active metal layer, and wherein bonding at least the active metal laminate and the barrier layer laminate comprises bonding the second active metal layer to the bonding layer of the active metal laminate.
Claim 58
Dependent Claim
32 words
The method of claim 52 , wherein the active metal laminate further comprises a current collector affixed to a side of the single active metal layer that is opposite the bonding layer.
Claim 59
Dependent Claim
49 words
The method of claim 48 ,wherein the barrier layer laminate further comprises (a) a second active metal layer disposed on a side of the barrier layer opposite the substrate and (b) a second bonding layer disposed on a side of the second active metal layer opposite the barrier layer.
Claim 60
Dependent Claim
55 words
The method of claim 54 , wherein the active metal laminate comprises the bonding layer and a single active metal layer, and wherein bonding at least the active metal laminate and the barrier layer laminate comprises bonding the second bonding layer of the barrier layer laminate to the bonding layer of the active metal laminate.
Claim 61
Dependent Claim
32 words
The method of claim 55 , wherein the active metal laminate further comprises a current collector affixed to a side of the single active metal layer that is opposite the bonding layer.
Claim 62
Independent Claim
86 words
A method of fabricating an active metal electrode including a barrier layer forming a substantially impervious layer which is conductive to ions of the active metal, the method comprising: (a) forming the barrier layer on a metal bonding layer to create a barrier layer laminate, the bonding layer being capable of forming a bond with the active metal; and (b) bonding the barrier layer laminate to a layer of active metal by affixing the active metal layer to the bonding layer of the barrier layer laminate.
Claim 63
Independent Claim
86 words
A method of fabricating an active metal electrode including a barrier layer forming a substantially impervious layer which is conductive to ions of the active metal, the method comprising: (a) forming the barrier layer on a metal bonding layer to create a barrier layer laminate, the bonding layer being capable of forming a bond with the active metal; and (b) bonding the barrier layer laminate to a layer of active metal by affixing the active metal layer to the bonding layer of the barrier layer laminate.
Claim 64
Dependent Claim
19 words
The method of claim 57 , wherein the bonding layer is an aluminum foil or an aluminum alloy foil.
Claim 65
Dependent Claim
16 words
The method of claim 57 , wherein the active metal is lithium or a lithium alloy.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2005-07-01 | 2005-12-31 | 2006-07-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2009-07-01 | 2009-12-31 | 2010-07-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2013-07-01 | 2013-12-31 | 2014-07-02 | $7700.00 | Window Closed / Lapsed |