Lithium-metal batteries having improved dimensional stability and methods of manufacture

1. An anode cell for a lithium-metal battery, the anode cell comprising:

a container having a first portion and a second portion to form an enclosed cavity, the first portion electrically-conductive and chemically-stable to lithium metal, the second portion permeable to lithium ions and chemically-stable to lithium metal;

an anode comprising lithium metal and disposed within the enclosed cavity, the anode in contact with the first portion and the second portion;

wherein the enclosed cavity is configured such that volumetric expansion and contraction of the anode during charging and discharging is accommodated entirely therein;

wherein a volume of the enclosed cavity is larger in size than a volume of the anode disposed therein;

wherein the second portion separates the anode from an electrolyte disposed external to the enclosed cavity;

wherein the electrolyte comprises a lithium salt; and

wherein the second portion directly contacts the anode.

2. The anode cell of claim 1 , wherein the second portion comprises a lid for the first portion.

3. The anode cell of claim 1 , wherein the second portion comprises a multilayer stack.

4. The anode cell of claim 1 , wherein the enclosed cavity has a cross-sectional area that is constant along a longitudinal axis thereof.

5. The anode cell of claim 4 , wherein the enclosed cavity comprises an orifice having a perimeter that defines the cross-sectional area.

6. The anode cell of claim 5 , further comprising a permeable membrane disposed along an exterior surface of the second portion and opposite the orifice.

7. The anode cell of claim 5 , wherein the second portion is coupled to the first portion via a seal around the perimeter of the orifice.

8. A battery pack, comprising:

at least one lithium-metal battery having an anode cell electrochemically coupled to a cathode cell, the anode cell comprising:

a container having a first portion and a second portion to form an enclosed cavity, the first portion electrically-conductive and chemically-stable to lithium metal, the second portion permeable to lithium ions and chemically-stable to lithium metal,

an anode comprising lithium metal and disposed within the enclosed cavity, the anode in contact with the first portion and the second portion,

wherein the enclosed cavity is configured such that volumetric expansion and contraction of the anode during charging and discharging is accommodated entirely therein;

wherein a volume of the enclosed cavity is larger in size than a volume of the anode disposed therein;

wherein the second portion separates the anode from an electrolyte disposed external to the enclosed cavity;

wherein the electrolyte comprises a lithium salt; and

wherein the second portion directly contacts the anode.

9. The battery pack of claim 8 ,

wherein the enclosed cavity comprises an orifice having a perimeter; and

wherein the anode cell further comprises a permeable membrane disposed along an exterior surface of the second portion and opposite the orifice.

10. The battery pack of claim 9 , wherein the second portion of the container is coupled to the first portion of the container via a seal around the perimeter of the orifice.

11. The battery pack of claim 9 , wherein the cathode cell comprises:

a cathode active material in contact with the permeable membrane along an area opposite the orifice;

an electrolyte comprising at least one solvated lithium species; and

a cathode current collector in contact with the cathode active material.

12. The battery pack of claim 8 ,

wherein the at least one lithium-metal battery comprises a plurality of lithium-metal batteries arranged in a stacked sequence; and

wherein the stacked sequence alternates between a first junction formed by adjacent pairs of anode cells and a second junction formed by adjacent pairs of cathode cells.

13. The battery pack of claim 12 ,

wherein the at least one lithium-metal battery comprises the plurality of lithium-metal batteries arranged in the stacked sequence; and

wherein individual lithium-metal batteries within the stacked sequence have aligned polarities.

14. The battery pack of claim 8 ,

wherein the at least one lithium-metal battery comprises an array of lithium-metal batteries; and

wherein the first portion of the container for each lithium-metal battery defines a section of an extended first portion shared in common.

15. The anode cell of claim 1 , wherein the lithium salt comprises at least one of LiPF 6 , LiBF 4 , LiClO 4 , LiSO 3 CF 3 , LiN(SO 2 CF 3 ) 2 , LiBC 4 O 8 , Li[PF 3 (C 2 CF 5 ) 3 ], and LiC(SO 2 CF 3 ) 3 .

16. The anode cell of claim 1 , wherein the second portion comprises at least one of a lithium phosphorus oxynitride material, a lithium boron oxynitride material, a lithium boron oxide material, a lithium niobium oxide material, a lithium lanthanum zirconium oxide material, a lithium phosphorus sulfide material, a lithium tin sulfide material, and a lithium germanium phosphorus sulfide material.

17. The battery pack of claim 8 , wherein the lithium salt comprises at least one of LiPF 6 , LiBF 4 , LiClO 4 , LiSO 3 CF 3 , LiN(SO 2 CF 3 ) 2 , LiBC 4 O 8 , Li[PF 3 (C 2 CF 5 ) 3 ], and LiC(SO 2 CF 3 ) 3 .

18. The battery pack of claim 8 , wherein the second portion comprises at least one of a lithium phosphorus oxynitride material, a lithium boron oxynitride material, a lithium boron oxide material, a lithium niobium oxide material, a lithium lanthanum zirconium oxide material, a lithium phosphorus sulfide material, a lithium tin sulfide material, and a lithium germanium phosphorus sulfide material.