Method for the production of electrodes for fully solid batteries

Abstract

An electrode film of an all-solid-state battery, an all-solid-state battery, and an electrode of an all-solid-state battery, which are fabricated by a process that includes thermally consolidating an electrode film by sintering at a temperature that does not exceed a predetermined threshold of a lowest melting temperature between an anode material and an cathode material.

1 - 17 . (canceled) 
     
     
         18 . An electrode film for an all-solid-state battery, fabricated by a process comprising:
 providing a substrate;   depositing, via electrophoretic deposition, an electrode film on said substrate, the electrode film being composed of a suspension containing nanoparticles of electrode materials, the nanoparticles having an average particle size of less than less than 100 nm;   drying the deposited electrode film; and   thermally consolidating the dried electrode film by sintering at a temperature that does not exceed a predetermined threshold of a melting temperature of one the electrode materials having a lowest melting temperature from among the electrode materials.   
     
     
         19 . The electrode film of  claim 18 , wherein the predetermined threshold is 0.7 times the melting temperature of one of the electrode materials having a lowest melting temperature from among the electrode materials. 
     
     
         20 . The electrode film of  claim 18 , wherein the predetermined threshold is 0.5 times the melting temperature of one of the electrode materials having a lowest melting temperature from among the electrode materials. 
     
     
         21 . The electrode film of  claim 18 , wherein the predetermined threshold is 0.3 times the melting temperature of one of the electrode materials having a lowest melting temperature from among the electrode materials. 
     
     
         22 . The electrode film of  claim 18 , further comprising mechanically compacting the dried electrode film, one of before, or during, or after thermally consolidating the dried electrode film. 
     
     
         23 . The electrode film of  claim 22 , wherein at least one of thermally consolidating the dried electrode film and mechanically compacting the dried electrode film is done under a vacuum or an inert atmosphere. 
     
     
         24 . The electrode film of  claim 18 , wherein mechanically compacting the dried electrode film is done by application of a compression pressure between one of:
 20 and 100 MPa; and   40 and 60 MPa.   
     
     
         25 . The electrode film of  claim 18 , wherein the electrophoretic deposition is made by anaphoresis. 
     
     
         26 . The electrode film of  claim 18 , wherein the thickness of the electrode film is one of:
 less than 20 μm;   less than 10 μm; and   less than 5 μm.   
     
     
         27 . The electrode film of  claim 18 , wherein the suspensions does not contain any stabilizers. 
     
     
         28 . An all-solid-state battery, fabricated by a process comprising:
 forming an electrode by:   depositing an electrode film via electrophoretic deposition of nanoparticles of an anode material and a cathode material on a substrate, wherein the nanoparticles have an average particle size of less than or equal to 30 nm, and the thickness of the electrode film is less than 5 μm; and   thermally consolidating the electrode film by sintering at a temperature that does not exceed a predetermined threshold of a lowest melting temperature between the anode material and the cathode material.   
     
     
         29 . The all-solid-state battery of  claim 28 , wherein the predetermined threshold is 0.7 times the lowest melting temperature between the anode material and the cathode material. 
     
     
         30 . The all-solid-state battery of  claim 28 , wherein the predetermined threshold is 0.5 times the lowest melting temperature between the anode material and the cathode material. 
     
     
         31 . The all-solid-state battery of  claim 28 , wherein the predetermined threshold is 0.3 times the lowest melting temperature between the anode material and the cathode material. 
     
     
         32 . The all-solid-state battery of  claim 28 , wherein the porosity of the electrode film is less than one of 10%, 5%, and 2%. 
     
     
         33 . The all-solid-state battery of  claim 28 , further comprising, before thermally consolidating the electrode film, mechanically compacting the electrode film. 
     
     
         34 . An electrode of an all-solid-state battery, fabricated by a process comprising:
 forming an electrode film by electrophoretic deposition of nanoparticles of an anode material and a cathode material on a substrate, wherein the nanoparticles have an average particle size of less than or equal to 30 nm, and the thickness of the electrode film is less than 5 μm;   drying the deposited electrode film; and   thermally consolidating the dried electrode film by sintering at a temperature that does not exceed a predetermined threshold of a lowest melting temperature between the anode material and the cathode material.   
     
     
         35 . The electrode of  claim 34 , wherein the predetermined threshold is one of 0.7, 0.5, and 0.3 times the lowest melting temperature between the anode material and the cathode material. 
     
     
         36 . The electrode of  claim 34 , wherein the porosity of the electrode film is less than one of 10%, 5%, and 2%. 
     
     
         37 . The electrode film of  claim 18 , wherein the substrate is conductive.