Method of producing a durable electrochemical cell

Abstract

The invention provides a method of protecting an ion insertion material from the degradative effects of a liquid or gel-type electrolyte material by disposing a protective, solid ion conducting, electrically insulating, layer between the ion insertion layer and the liquid or gel-type electrolyte material. The invention further provides liquid or gel-type electrochemical cells having improved durability having a pair of electrodes, a pair of ion insertion layers sandwiched between the pair of electrodes, a pair of solid ion conducting layers sandwiched between the ion insertion layers, and a liquid or gel-type electrolyte material disposed between the solid ion conducting layers, where the solid ion conducting layer minimizes or prevents degradation of the faces of the ion insertion materials facing the liquid or gel-type electrolyte material. Electrochemical cells of this invention having increased durability include secondary lithium batteries and electrochromic devices.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:  
     
         1 . A method of producing a durable electrochemical cell, comprising: 
 (a) preparing a first electrode-equipped section by the method comprising: 
 (i) depositing a first ion insertion material on a first conducting material; and  
 (ii) depositing a first solid ion conducting material on said first ion insertion material;  
   (b) preparing a second electrode-equipped section by the method comprising 
 (i) depositing a second ion insertion material on a second conducting material; and  
 (ii) depositing a second solid ion conducting material on said second ion insertion material;  
   (c) disposing said first electrode-equipped section on said second electrode-equipped section, wherein said first solid ion conducting material is parallel to and spaced apart from said second solid ion conducting material by a plurality of spacers, wherein said first solid ion conducting material, said second ion conducting material, and said plurality of spacers define a void; and    (d) inserting a liquid or gel-type ion conducting material into said void.    
     
     
         2 . The method of  claim 1 , wherein said first and second solid ion conducting layers are lithium aluminum fluoride.  
     
     
         3 . The method of  claim 1 , wherein said first and second solid ion conducting layers are lithium phosphorous oxinitride.  
     
     
         4 . The method of  claim 1 , wherein said first ion insertion layer is a cathodic electrochromic material  
     
     
         5 . The method of  claim 1 , wherein said second ion insertion layer is an anodic electrochromic material.  
     
     
         6 . The method of  claim 1 , wherein said first ion insertion layer is selected from the group consisting of transition metal oxides, transition metal sulfides, transition metal oxysulfides, transition metal halides, selenides, tellurides, chromates, molybdates, tungstates, vanadates, niobates, tantalates, titanates, stannates.  
     
     
         7 . The method of  claim 6 , wherein said first ion insertion layer is tungsten oxide.  
     
     
         8 . The method of  claim 1 , wherein said second ion insertion layer is selected from the group consisting of V 2 O 5 , IrO 2 , and NiO 2 .  
     
     
         9 . The method of  claim 8 , wherein said second ion insertion layer is V 2 O 5 .  
     
     
         10 . The method of  claim 1 , wherein said first and second solid electrolyte layers have a thickness of about 1000 to 5000 Angstroms.  
     
     
         11 . The method of  claim 1 , further comprising, prior to step (a)(i), depositing said first conducting material on a first substrate, and prior to step (b)(i), depositing said second conducting material on a second substrate.