Methods of producing batteries utilizing anode metal depositions directly on nanoporous separators
Provided are methods of preparing a separator/anode assembly for use in an electric current producing cell, wherein an electroactive anode metal layer, such as a lithium metal layer, is deposited directly on a porous separator, such as a nanoporous separator layer.
1. A method of making a separator/anode assembly for use in an electric current producing cell comprising the steps of:
(a) coating a porous separator layer directly on a substrate;
(b) depositing an anode layer directly on said porous separator layer, wherein said anode layer comprises an electroactive anode metal; and
(c) delaminating said porous separator layer from said substrate to form the separator/anode assembly.
2. The method of claim 1 , wherein said electroactive anode metal comprises lithium metal.
3. The method of claim 1 , wherein said electroactive anode metal comprises an alloy of lithium.
4. The method of claim 1 , wherein said depositing of said anode layer comprises a vapor deposition.
5. The method of claim 2 , wherein said depositing of said anode layer comprises a vapor deposition.
6. The method of claim 3 , wherein depositing of said anode layer comprises a vapor deposition.
7. The method of claim 1 , wherein said porous separator layer comprises a xerogel layer.
8. The method of claim 1 , wherein said porous separator layer has a thickness of less than 9 microns.
9. The method of claim 1 , wherein said porous separator layer comprises aluminum boehmite.
10. The method of claim 1 , wherein said porous separator layer is nanoporous.
11. A method of making a separator/anode assembly for use in an electric current producing cell comprising the steps of:
(a) coating a porous separator layer directly on a porous substrate, and
(b) depositing an anode layer directly on said porous separator layer, wherein said anode layer comprises an electroactive anode metal.
12. The method of claim 11 , wherein said porous substrate is selected from the group consisting of porous polymer films and porous non-woven polymer fiber substrates.
13. A method of making a separator/anode assembly for use in an electric current producing cell comprising the steps of:
(a) coating a porous separator layer directly on a substrate;
(b) depositing an anode layer directly on said porous separator layer, wherein said anode layer comprises an electroactive anode metal;
(c) depositing an anode current collector layer on said anode layer; and
(d) delaminating said porous separator layer from said substrate to form the separator/anode assembly.
14. The method of claim 13 , wherein said anode layer comprises lithium metal.
15. The method of claim 13 , wherein said anode current collector layer comprises copper.
16. The method of claim 13 , wherein said anode current collector layer has a thickness of less than 3 microns.
17. The method of claim 13 , wherein the depositing step (c) comprises laminating the anode current collector layer on said anode layer.