Methods of producing batteries utilizing anode coatings directly on nanoporous separators
Provided are methods of preparing a separator/anode assembly for use in an electric current producing cell, wherein the assembly comprises an anode current collector layer interposed between a first anode layer and a second anode layer and a porous separator layer on the side of the first anode layer opposite to the anode current collector layer, wherein the first anode layer is coated directly on the separator layer.
1. A method of making a cell for a lithium battery comprising the steps of:
(a) providing a separator/anode assembly made by a method comprising the steps of:
(i) providing a first porous separator layer;
(ii) depositing a first anode layer directly on said porous separator layer;
(iii) depositing an anode current collector layer on said first anode layer; and
(iv) providing a second anode layer on said anode current collector layer;
(b) providing a cathode assembly which comprises a current collector layer interposed between two cathode layers; and
(c) interleaving the cathode assembly and separator/anode assembly such that said cathode assembly is adjacent to the separator layer of said separator/anode assembly, so as to make said cell.
2. The method of claim 1 , wherein said anode layer comprises an electroactive anode metal.
3. The method of claim 2 , wherein said electroactive anode metal comprises lithium or an alloy of lithium.
4. The method of claim 1 , wherein said depositing of said first anode layer comprises vapor deposition.
5. The method of claim 1 , wherein said porous separator layer has a thickness of less than 9 microns.
6. The method of claim 1 , wherein said porous separator layer has a thickness of less than 6 microns.
7. The method of claim 1 , wherein said porous separator layer comprises aluminum boehmite.
8. The method of claim 1 , wherein step (a)(i) further comprises depositing the porous separator layer on a substrate.
9. The method of claim 8 , further comprising, after step (a)(iv):
(v) delaminating said porous separator layer from said substrate.
10. The method of claim 8 , wherein said substrate is a porous substrate.
11. The method of claim 10 , wherein said porous substrate is selected from the group consisting of porous polymer films and porous non-woven polymer fiber substrates.
12. The method of claim 1 , wherein said anode current collector layer comprises copper.
13. The method of claim 1 , wherein said anode current collector layer has a thickness of less than 3 microns.
14. The method of claim 1 , further comprising providing one or multiple cells, made by the method, in a casing or pack.
15. The method of claim 14 , further comprising providing an electrolyte therein, so as to provide a lithium battery.
16. The method of claim 15 , wherein said electrolyte comprises a liquid electrolyte, a gel polymer electrolyte, or a solid polymer electrolyte.
17. A method of making a cell for a lithium battery comprising the steps of:
(a) providing a separator/anode assembly made by a method comprising the steps of:
(i) providing a first porous separator layer;
(ii) depositing a first anode layer directly on said porous separator layer, wherein said anode layer comprises an electroactive anode metal;
(iii) laminating an anode current collector layer on said first anode layer;
(iv) depositing a second anode layer on said anode current collector layer; and
(v) providing a second porous separator layer on said second anode layer;
(b) providing a cathode assembly which comprises a current collector layer interposed between two cathode layers; and
(c) interleaving the cathode assembly and separator/anode assembly such that said cathode assembly is adjacent to the separator layer of said separator/anode assembly, so as to make said cell.
18. The method of claim 17 , wherein step (a)(i) further comprises depositing the porous separator layer on a substrate.
19. The method of claim 18 , further comprising, after step (a)(iv):
(v) delaminating said porous separator layer from said substrate.
20. The method of claim 17 , wherein said anode current collector layer comprises copper.
21. The method of claim 17 , wherein said anode current collector layer has a thickness of less than 3 microns.
22. The method of claim 17 , wherein said porous separator layer has a thickness of less than 9 microns.
23. The method of claim 17 , further comprising providing one or multiple cells, made by the method, in a casing or pack.
24. The method of claim 23 , further comprising providing an electrolyte therein, so as to provide a lithium battery.
25. The method of claim 24 , wherein said electrolyte comprises a liquid electrolyte, a gel polymer electrolyte, or a solid polymer electrolyte.
26. A lithium battery made by the method of claim 15 .
27. A lithium battery made by the method of claim 24 .
28. The method of claim 1 , further comprising, after step (a)(iv):
(v) providing a second porous separator layer on said second anode layer.
29. The method of claim 1 , wherein step (b) further comprises providing a second porous separator layer on one or both of said two cathode layers.
30. The method of claim 17 , wherein said electroactive anode metal comprises lithium metal.
31. The method of claim 17 , wherein said electroactive anode metal comprises an alloy of lithium.
32. The method of claim 17 , wherein said depositing of said first anode layer comprises vapor deposition.