Lithium oxygen batteries having a carbon cloth current collector and method of producing same

Abstract

A lithium oxygen or air battery (80) is disclosed having two halves (81) that are joined together along their edges. Each battery half (81) has a carbon cloth or mesh cathode current collector (82), a cathode (83), a cathode terminal (84), an anode (85), an anode current collector, anode terminal (88) and a solid separator (87). The cathode includes randomly distributed carbon fibers throughout. The manufacturing of the cathode includes embedding a carbon cloth between two layers of cathode material in a slurry state

1 - 8 . (canceled) 
     
     
         9 . A method of producing a lithium oxygen cathode comprising the steps of:
 (a) providing a cathode material slurry having a polymer binder, a mass of carbon powder, and a mass of random carbon fibers;   (b) depositing a first quantity of cathode material slurry to form a first layer of cathode material;   (c) depositing a carbon cloth upon the first layer of cathode material, and   (d) depositing a second quantity of cathode material slurry upon the carbon cloth to form a second layer of cathode material,   whereby the cathode has both an embedded carbon cloth current collector and randomly distributed carbon fibers throughout the cathode.   
     
     
         10 . The method of  claim 9  wherein the carbon cloth is selected from the group consisting of carbon mesh, carbon fabric, carbon yarn, carbon mat, and carbon paper. 
     
     
         11 . A method of producing a lithium oxygen battery comprising the steps of:
 (a) providing a cathode material slurry having a polymer binder, a mass of carbon powder, and a mass of random carbon fibers;   (b) depositing a quantity of cathode material slurry to form a layer of cathode material;   (c) embedding a carbon cloth into the layer of cathode material to form a cathode current collector;   (d) depositing a separator upon the cathode material;   (e) depositing a lithium anode upon the separator, and   (f) depositing an anode current collector upon the anode,   whereby the cathode has both an embedded carbon cloth current collector and randomly distributed carbon fibers through the cathode.   
     
     
         12 . The method of  claim 10  wherein the carbon cloth is selected from the group consisting of carbon mesh, carbon fabric, carbon yarn, carbon mat, and carbon paper.