SOLID-STATE BATTERY SEPARATORS AND METHODS OF FABRICATION
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.