THIN-FILM BATTERIES WITH POLYMER AND LiPON ELECTROLYTE LAYERS AND METHOD

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., LiCoO 2 ) 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.

1 - 31 . (canceled) 
     
     
         32 . A method of forming a battery cell having a composite electrolyte structure comprising:
 a) providing a positive electrode component;   b) providing a negative electrode component;   c) depositing a first electrolyte layer having randomly spaced defects therein on the negative electrode component;   d) depositing a second electrolyte layer having randomly spaced defects therein on a positive electrode component;   e) providing a third electrolyte material that comprises a polymer or a gel that is soft compared to the first and second electrolyte layers;   f) laminating the first electrolyte layer on the negative electrode to the second electrolyte layer on the positive electrode using a the third soft electrolyte material to at least partially fill and fix the defects in at least one of the first and second electrolyte layers to form a the composite electrolyte structure of a the battery cell;   wherein the third electrolyte layer is applied as a liquid and then dried.   
     
     
         33 . The method of claim  1 , wherein the third electrolyte layer is applied as a dip coating. 
     
     
         34 . The method of claim  1 , wherein the third electrolyte layer is spun on. 
     
     
         35 . The method of claim  1 , wherein the third electrolyte layer is cast on. 
     
     
         36 . The method of claim  1 , wherein the third electrolyte layer is deposited from a liquid source and squeegeed and/or doctor-bladed in place. 
     
     
         37 . The method of claim  1 , wherein the third electrolyte layer is printed to areas to which the third electrolyte is desired. 
     
     
         38 . The method of claim  1 , wherein the first and second electrolyte layers are LiPON. 
     
     
         39 . The method of claim  7 , wherein the third electrolyte layer comprises polyvinylidene difluoride, propylene carbonate, and a lithium salt. 
     
     
         40 . The method of claim  7 , wherein the third electrolyte layer comprises MEEP. 
     
     
         41 . The method of claim  7 , wherein the third electrolyte layer comprises a polyphosphazene and a lithium salt. 
     
     
         42 . A battery cell having a negative electrode, a positive electrode, and an electrolyte structure, wherein
 a) the negative electrode includes a first electrolyte layer covering at least a portion of the negative electrode and having randomly spaced defects;   b) the positive electrode includes a cathode material and a second electrolyte layer covering at least a portion of the positive electrode and having randomly spaced defects; and   c) the electrolyte structure includes a third electrolyte material that comprises a polymer or a gel that is soft compared to the first and second electrolyte layers sandwiched between the first electrolyte of the negative electrode and the second electrolyte layer of the positive electrode;   
       wherein the randomly spaced defects in the first and second electrolyte layers are at least partially filled by the third soft electrolyte material and wherein the third soft electrolyte layer fixes defects in at least one of the first and second electrolyte layers. 
     
     
         43 . The battery cell of claim  11  wherein the positive electrode current-collector material includes a metal mesh around which the cathode material is deposited. 
     
     
         44 . The battery cell of claim  11 , wherein the negative electrode includes a negative-electrode current collector made of a metal that does not readily alloy with lithium during a plating operation, and lithium metal is plated onto the negative-electrode current collector through the first electrolyte layer covering the negative electrode. 
     
     
         45 . The battery cell of claim  11 , wherein the negative electrode includes a mask layer that covers a periphery of the negative-electrode current collector and lithium metal is plated through the first electrolyte layer covering the negative electrode onto an area of the metal negative-electrode current collector defined by the mask. 
     
     
         46 . The battery cell of claim  11 , wherein: the negative electrode includes a current-collector metal layer and an anode material, and the anode material includes lithium metal deposited on at least one of two major faces of the metal layer, which is at least partially covered by the first electrolyte layer of the negative electrode. 
     
     
         47 . The battery cell of claim  11 , wherein: the anode material is deposited on both major faces of the metal layer of the negative electrode, each face at least partially covered by the first electrolyte layer of the negative electrode. 
     
     
         48 . The battery cell of claim  11 , wherein: the positive electrode includes a current-collector metal layer, and the cathode material is deposited on both major faces of the metal layer and is at least partially covered by the second electrolyte layer. 
     
     
         49 . The battery cell of claim  11 , wherein: the negative electrode includes a current-collector metal layer and an anode material, and the anode material includes lithium metal plated onto both major faces of the negative-electrode current-collector metal layer through the first electrolyte layer covering the negative electrode. 
     
     
         50 . The battery cell of claim  11 , further comprising: an encapsulating material surrounding the battery cell; and one or more electrical leads connecting from the battery cell to an exterior of the encapsulating material. 
     
     
         51 . The battery cell of claim  11 , further comprising: an electronic device; and a housing holding the electronic device, wherein the battery cell is within the housing and supplies power to the electronic device. 
     
     
         52 . The battery cell of claim  11 , wherein: the positive electrode comprises oxides of copper.