Energy device with lithium

Abstract

An energy device has an electrode including lithium cobaltite (LCO) grains, where the LCO grains are sintered to one another forming a self-supporting sheet with porous passages. The porous passages wind and branch through the sheet. The energy device further includes a solid electrolyte comprising lithium phosphosulfide (LPS) overlaying a major surface of the sheet and extending into the porous passages. The sheet serves as mechanical support for the solid electrolyte, allowing for high temperature joining of the LPS to the LCO without binder in the LPS.

What is claimed is: 
     
         1 . An energy device, comprising:
 an electrode comprising a ceramic sheet, wherein the ceramic comprises lithium, wherein the sheet is porous, wherein porosity of the sheet is such that pores open to surfaces of the sheet and pores open to one another and are connected to one another within the sheet forming passages that wind and branch through the sheet; and   a solid electrolyte comprising lithium overlaying a first major surface of the porous sheet of the electrode and extending into the passages of the sheet, wherein the solid electrolyte is an amorphous glassy solid electrolyte having a melting temperature above 200° C.,   the solid electrolyte is also overlaying a second major surface of the sheet of the electrode, and wherein the solid electrolyte extends through the passages and connects together the solid electrolyte overlaying the first and second surfaces.   
     
     
         2 . The energy device of  claim 1 , wherein the solid electrolyte overlaying the first major surface of the sheet of the electrode has a density of at least 90%. 
     
     
         3 . The energy device of  claim 1 , further comprising a current collector, wherein the current collector overlays, directly contacts, and electrically connects to the solid electrolyte. 
     
     
         4 . The energy device of  claim 1 , wherein the ceramic sheet of the electrode mechanically supports the solid electrolyte and correspondingly geometrically constrains the solid electrolyte such that, in terms of area, a footprint of the solid electrolyte facing the ceramic sheet of the electrode is not greater than 120% of a footprint of the first major surface of the sheet of the electrode. 
     
     
         5 . The energy device of  claim 1 , wherein at least some of the passages have a length of at least 10 μm, and wherein the solid electrolyte extends into at least some of the passages a distance of at least 3 μm inward from the first major surface. 
     
     
         6 . The energy device of  claim 5 , wherein the ceramic sheet of the electrode has a thickness greater than 10 μm and less than 100 μm, and the solid electrolyte extends outward from the first major surface by less than 100 μm, thereby facilitating a particularly thin device. 
     
     
         7 . The energy device of  claim 1 , wherein porosity of the ceramic sheet of the electrode is at least 15% by volume. 
     
     
         8 . An energy device, comprising:
 an electrode comprising a ceramic sheet, wherein the ceramic comprises lithium, wherein the sheet is porous, wherein porosity of the sheet is such that pores open to surfaces of the sheet and pores open to one another and are connected to one another within the sheet forming passages that wind and branch through the sheet; and   a solid electrolyte comprising lithium wherein the solid electrolyte overlays a first major surface extends into the passages, wherein the solid electrolyte is an amorphous glassy solid electrolyte having a melting temperature above 200° C.,   wherein at least some of the passages have a length of at least 10 μm, and wherein the solid electrolyte extends into at least some of the passages a distance of at least 3 μm inward from the first major surface.   
     
     
         9 . The energy device of  claim 8 , wherein the solid electrolyte has a density of at least 90%. 
     
     
         10 . The energy device of  claim 8 , further comprising a current collector, wherein the current collector overlays, directly contacts, and electrically connects to the solid electrolyte. 
     
     
         11 . The energy device of  claim 8 , wherein the ceramic sheet mechanically supports the solid electrolyte and correspondingly geometrically constrains the solid electrolyte such that, in terms of area, a footprint of the solid electrolyte facing the first major surface of the ceramic sheet is not greater than 120% of a footprint of the first major surface. 
     
     
         12 . The energy device of  claim 8 , wherein the ceramic sheet has a thickness greater than 10 μm and less than 100 μm, and the solid electrolyte extends outward from the first and second major surface by less than 100 μm. 
     
     
         13 . An energy device, comprising:
 an electrode comprising a ceramic sheet, wherein the ceramic comprises lithium, wherein the sheet is porous, wherein porosity of the sheet is such that pores open to surfaces of the sheet and pores open to one another and are connected to one another within the sheet forming passages that wind and branch through the sheet;   a solid electrolyte comprising lithium overlaying a first major surface of the ceramic sheet and extending into the passages, wherein the solid electrolyte is an amorphous glassy solid electrolyte having a melting temperature above 200° C.; and   a current collector, wherein the device is anode-less such that the current collector overlays, directly contacts, and electrically connects to the solid electrolyte.   
     
     
         14 . The energy device of  claim 13 , wherein the ceramic sheet mechanically supports the solid electrolyte and correspondingly geometrically constrains the solid electrolyte such that, in terms of area, a footprint of the solid electrolyte facing the ceramic sheet is not greater than 120% of a footprint of the first major surface of the ceramic sheet. 
     
     
         15 . The energy device of  claim 13 , wherein at least some of the passages have a length of at least 10 μm, and wherein the solid electrolyte extends into at least some of the passages a distance of at least 3 μm inward from the first major surface. 
     
     
         16 . The energy device of  claim 13 , wherein the ceramic sheet has a thickness greater than 10 μm and less than 100 μm, and the solid electrolyte extends outward from the first major surface by less than 100 μm. 
     
     
         17 . An energy device, comprising:
 an electrode comprising a ceramic sheet, wherein the ceramic comprises lithium, wherein the sheet is porous, wherein porosity of the sheet is such that pores open to surfaces of the sheet and pores open to one another and are connected to one another within the sheet forming passages that wind and branch through the sheet; and   a solid electrolyte comprising lithium overlaying both a first major surface and a second major surface of the ceramic sheet and extending into the passages, wherein the solid electrolyte is an amorphous glassy solid electrolyte having a melting temperature above 200° C.,   wherein the energy device is substrate-free such that the ceramic sheet mechanically supports the solid electrolyte, and correspondingly geometrically constrains the solid electrolyte such that an area of a footprint of the solid electrolyte facing the ceramic sheet is not greater than 120% of area of a footprint of the first major surface of the ceramic sheet.   
     
     
         18 . The energy device of  claim 17 , further comprising a current collector overlaying, directly contacting, and electrically connected to the solid electrolyte. 
     
     
         19 . The energy device of  claim 17 , wherein at least some of the passages have a length of at least 10 μm, and wherein the solid electrolyte extends into at least some of the passages a distance of at least 3 μm inward from the first major surface. 
     
     
         20 . The energy device of  claim 17 , wherein the ceramic sheet has a thickness greater than 10 μm and less than 100 μm, and the solid electrolyte extends outward from the first major surface by less than 100 μm.