Electrolytes for intercalated lithium batteries

Abstract

An intercalated lithium battery that has been fabricated in open air with a thin dense layer of amorphous solid-state lithium borate electrolyte deposited directly onto a negative electrode via flame spray pyrolysis. In one embodiment, the negative electrode is attached to a prefabricated positive electrode via hot pressing (embossing), thus forming an intercalated lithium battery. The method significantly improves upon current methods of fabricating thin film solid state batteries by permitting fabrication without the aid of a controlled environment, thereby allowing for significantly cheaper fabrication than prior batch methods.

1 . An electrolyte that has been manufactured at an oxygen partial pressure between 1×10{circumflex over ( )}−3 Pa and 1×10{circumflex over ( )}8 Pa and wherein the electrolyte comprises an amorphous lithium metaborate layer containing about 0.1 weight percent to 10 weight percent carbon. 
     
     
         2 . The electrolyte of  claim 1  wherein said oxygen partial pressure is approximately 1×10{circumflex over ( )}5 Pa. 
     
     
         3 . The electrolyte of  claim 1  wherein said oxygen partial pressure is between 1×10{circumflex over ( )}2 Pa and 1×10{circumflex over ( )}6 Pa 
     
     
         4 . The electrolyte of  claim 1  wherein the electrolyte is manufactured in ambient atmosphere. 
     
     
         5 . A method of manufacturing an electrolyte comprising the step of forming the electrolyte in an atmosphere having an oxygen partial pressure between 1×10{circumflex over ( )}−3 Pa and 1×10{circumflex over ( )}8 Pa and wherein the electrolyte is formed to comprise an amorphous lithium metaborate layer that includes about 0.1 weight percent to 10 weight percent carbon. 
     
     
         6 . The method of  claim 5 , wherein the oxygen partial pressure is approximately 1×10{circumflex over ( )}5 Pa. 
     
     
         7 . The method of  claim 5  wherein the oxygen partial pressure is between 1×10{circumflex over ( )}2 Pa and 1×10{circumflex over ( )}6 Pa 
     
     
         8 . The battery of  claim 5  wherein the atmosphere is an ambient atmosphere. 
     
     
         9 . A solid thin film that has been manufactured at an oxygen partial pressure between 1×10{circumflex over ( )}−3 Pa and 1×10{circumflex over ( )}8 Pa and wherein the thin film comprises an amorphous lithium metaborate layer containing about 0.1 weight percent to 10 weight percent carbon. 
     
     
         10 . The solid thin film of  claim 9  wherein said oxygen partial pressure is approximately 1×10{circumflex over ( )}5 Pa. 
     
     
         11 . The solid thin film of  claim 9  wherein said oxygen partial pressure is between 1×10{circumflex over ( )}2 Pa and 1×10{circumflex over ( )}6 Pa 
     
     
         12 . The solid thin film of  claim 9  wherein the electrolyte is manufactured in ambient atmosphere.