Electrolyte material composition and method

Abstract

The electrolyte material includes a polymer, a salt, and a solvent. The electrolyte material has a viscosity in the range from about 3.0 cP to about 20.0 cP such that the electrolyte material can be applied to a substrate using an ink jet print head.

We claim: 
     
         1 . An electrolyte material comprising a polyimide polymer, a lithium salt, and a solvent, wherein the electrolyte material has a viscosity in the range from about 3.0 to 8.0 cP such that the electrolyte material can be applied to a surface in a layer using an ink jet print head. 
     
     
         2 . The electrolyte material of  claim 1 , wherein the electrolyte material has a dynamic surface tension in the range from about 30 dynes/cm to about 50 dynes/cm. 
     
     
         3 . The electrolyte material of  claim 1 , wherein the polymer comprises a terpolymer poly (pyromellitic dianhydride+3,3′,5,5′-tetramethyl-4,4′-methylene dianiline/2,4,6-trimethyl-1,3-phenylenediamineDimide (poly (PDMA+TMMDA/DAMs)imide). 
     
     
         4 . The electrolyte material of  claim 3 , wherein the solvent is present in an amount ranging from about 80.0% to about 98.0% by weight. 
     
     
         5 . The electrolyte material of  claim 4 , wherein the polymer is present in an amount from about 0.5% to about 2.5% by weight. 
     
     
         6 . The electrolyte material of  claim 1 , wherein the salt comprises lithium bis trifluoromehtanesulfonimide. 
     
     
         7 . The electrolyte material of  claim 1 , wherein the solvent is selected from the group consisting of gamma butyrolactone, n-methyl-pyrrolidone, n-gamma valerolactone, N-methyl-2-pyrrolidinone, 3-methyl-oxazolidinone, tetramethylurea, dimethylsulfoxide, dimethylformamide, dimethylacetamide, methylethylketone, methyl isobutyl ketone, ethylene carbonate, propylene carbonate, dimethyl carbonate, ethylmethylcarbonate, diethylcarbonate, dimethoxyethane, dimethoxymethane, diethoxyethane, tetrahydrofuran, 2-methyl-tetrahydrofuran, 1,3-dioxolane, 4-methyl-1,3-dioxolane, 2-methyl-1,3-dioxolane, acetonitrile, methylacetate, ethylacetate, methyl butyrate, ethyl butyrate or any polar aprotic solvent and mixtures thereof. 
     
     
         8 . The electrolyte material of  claim 7 , wherein the solvent comprises gamma butyrolactone. 
     
     
         9 . The electrolyte material of  claim 1 , further comprising a surface tension modifier. 
     
     
         10 . The electrolyte material of  claim 1 , further comprising a co-solvent. 
     
     
         11 . The electrolyte material of  claim 1 , wherein the layer has a thickness in the range of from about 10 micrometers to about 30 micrometers. 
     
     
         12 . The electrolyte material of  claim 11 , wherein the layer has a thickness in the range of from about 16 micrometers to about 22 micrometers. 
     
     
         13 . The electrolyte material of  claim 1 , wherein the surface comprises one of a substrate and an intermediate layer disposed atop the substrate. 
     
     
         14 . The electrolyte material of  claim 13 , wherein the intermediate layer comprises one of an adhesive material, a cathode material, an anode material, or an insulating material. 
     
     
         15 . The electrolyte material of  claim 1 , further comprising a device for use in an ink jet print operation comprising:
 a housing;   a series of ejection nozzles mounted within the housing, each ejection nozzle capable of ejecting a drop on demand; and   a source of the electrolyte material communicating with the nozzles.   
     
     
         16 . An electrolyte adapted to be applied using an ink jet print head, comprising:
 from about 0.5% to about 2.5% by weight of a polyimide polymer;   a lithium salt; and   from about 80.0% to about 98.0% by weight of a solvent;   wherein the electrolyte has a viscosity in the range from about 3.0 to 8.0 cP such that the electrolyte can be jetted by the ink jet print head.   
     
     
         17 . The electrolyte of  claim 16 , wherein the polymer is present in the amount ranging from about 1.0% to about 1.5% by weight; wherein the lithium salt is present in the amount ranging from about 2.0% to about 3.0% by weight; wherein the solvent is present in the amount ranging from about 95.0% to about 98.0% by weight. 
     
     
         18 . The electrolyte of  claim 16 , wherein the electrolyte has a dynamic surface tension in the range from about 30 dynes/cm to about 50 dynes/cm. 
     
     
         19 . A method of manufacturing a battery using an ink jet print head comprising the steps of:
 jetting an electrolyte material onto a surface, wherein the electrolyte material comprises a polyimide polymer, a lithium salt, and a solvent and has a viscosity in the range from about 3.0 cP to about 8.0 cP; and   vaporizing a portion of the solvent.   
     
     
         20 . The method of  claim 19 , wherein the electrolyte material has a dynamic surface tension in the range from about 30 dynes/cm to about 50 dynes/cm. 
     
     
         21 . The method of  claim 19 , wherein the electrolyte material forms a layer having a thickness in the range of from about 10 micrometers to about 30 micrometers. 
     
     
         22 . The method of  claim 21 , wherein the thickness is in the range of from about 18 micrometers to about 22 micrometers. 
     
     
         23 . The method of  claim 19 , wherein the substrate is heated to promote vaporization of the solvent. 
     
     
         24 . The method of  claim 19 , wherein the electrolyte material is jetted from an ink jet print head, and the method further comprises relative movement of the ink jet print head over the substrate to form a layer thereon. 
     
     
         25 . The method of  claim 24 , wherein the relative movement includes up to 50 passes. 
     
     
         26 . The method of  claim 25 , wherein the relative movement includes between 20 and 30 passes.