Solid-state battery separators and methods of fabrication

Abstract

Embodiments of solid-state batteries, battery components, and related construction methods are described. The components include one or more embodiments of a low melt temperature electrolyte bonded solid-state rechargeable battery electrode and one or more embodiments of a composite separator having a low melt temperature electrolyte component. Embodiments of methods for fabrication of solid-state batteries and battery components are described. These methods include co-extrusion, hot pressing and roll casting.

1 .- 20 . (canceled) 
     
     
         21 . A method of fabricating a solid-state battery comprising:
 receiving a cathode current collector foil substrate; and   roll casting a cathode slurry on the cathode current collector foil substrate to form a cathode casting.   
     
     
         22 . The method of  claim 21 , wherein the roll casting comprises:
 applying the cathode slurry to the cathode current collector foil substrate;   controlling the thickness of the applied cathode slurry with a doctor blade;   drying the cathode slurry in a drying oven; and   bonding the dried cathode slurry to the cathode current collector foil substrate with hot press rollers.   
     
     
         23 . The method of  claim 21 , further comprising:
 roll casting an electrolyte separator slurry on the cathode casting to form an electrolyte bonded and coated cathode casting.   
     
     
         24 . The method of  claim 23 , further comprising:
 roll casting an anode slurry on the electrolyte bonded and coated cathode casting.   
     
     
         25 . The method of  claim 24 , further comprising:
 bonding cathode current collector foil to the cathode; and   bonding anode current collector foil to the anode.   
     
     
         26 . The method of  claim 25 , wherein the bonding is achieved using hot press rolling. 
     
     
         27 . A method for fabrication of a solid-state battery comprising:
 coextruding cathode material and separator material; and   laminating a cathode current collector foil to the cathode material by hot press rolling.   
     
     
         28 . The method of  claim 27 , further comprising:
 coextruding anode material with the cathode material and the separator material.   
     
     
         29 . The method of  claim 27 , further comprising:
 applying an anode by evaporative deposition.   
     
     
         30 . The method of  claim 29 , further comprising:
 controlling the application of the anode with a continuous mask.   
     
     
         31 . The method of  claim 29 , further comprising:
 applying the anode current collector to the anode by hot pressing an anode current collecting foil to the anode.   
     
     
         32 . A system comprising:
 a solid-state battery, the solid state battery comprising:   a cathode including lithium active powders, electrolyte powders, and electrically conductive carbon nanotubes, the lithium active particles being individually coated with a film of ion conductive glass; and   a separator comprising:   ionic, conductive filler powder; and   a first meltable inorganic solid electrolyte configured to bond together the ionic, conductive filler powder.   
     
     
         33 . The system of  claim 32 , further comprising:
 a coating of lithium metal applied onto the separator to form an anode for the solid-state battery.   
     
     
         33 . The system of  claim 33 , wherein the anode is applied to the separator by evaporative deposition. 
     
     
         35 . The system of  claim 32 , further comprising an anode bonded to the separator, the anode comprising:
 an active anode powder;   an ion conductive electrolyte powder;   an electrically conductive powder; and   a second meltable inorganic solid electrolyte configured to bond together th active anode powder, the ion conductive electrolyte powder and the electrically conductive powder.   
     
     
         36 . The system of  claim 32 , wherein the inorganic solid electrolyte is meltable at a maximum reaction temperature of about 500° C. 
     
     
         37 . The system of  claim 32 , wherein the separator is coextruded with cathode material.