Solid-state electrode having integrated sulfide separator

Abstract

In general, a solid-state electrode includes an electrode composite layer comprising a plurality of active material particles mixed with a solid electrolyte buffer material comprising a first plurality of solid electrolyte particles layered onto and directly contacting a current collector foil, and an electrically non-conductive separator layer comprising a second plurality of solid electrolyte particles layered onto and directly contacting the electrode composite layer. In some examples, an interpenetrating boundary layer is disposed between the electrode composite layer and the electrically non-conductive separator layer. In some examples, the electrode composite layer includes one or more conductive additives intermixed with the plurality of active material particles, and the electrode composite layer is electrically conductive. In some examples, the electrode composite layer is adhered together by a binder.

1 - 7 . (canceled) 
     
     
         8 . A solid-state electrochemical cell comprising:
 a first electrode, the first electrode comprising:
 a current collector; 
 a first electrically conductive electrode layer layered onto and directly contacting the current collector, the first electrode layer including a first plurality of active material particles mixed with a first plurality of solid electrolyte buffer particles, wherein the first plurality of solid electrolyte buffer particles comprise sintered sulfide ceramic particles; 
 a first electrically non-conductive separator layer layered onto and directly contacting the first electrode layer, the first separator layer including a second plurality of solid electrolyte buffer particles, wherein the second plurality of solid electrolyte buffer particles comprise sintered sulfide ceramic particles; and 
 an interpenetrating boundary between the first electrically conductive electrode layer and the first electrically non-conductive separator layer. 
   
     
     
         9 . (canceled) 
     
     
         10 . The solid-state electrochemical cell of  claim 8 , further comprising:
 a second electrically non-conductive separator layer layered onto and directly contacting the first separator layer, the second separator layer including a third plurality of solid electrolyte buffer particles; and   an interpenetrating boundary between the first separator layer and the second separator layer.   
     
     
         11 . The solid-state electrochemical cell of  claim 10 , wherein the third plurality of solid electrolyte buffer particles comprise a sulfide ceramic. 
     
     
         12 . The solid-state electrochemical cell of  claim 8 , wherein an average grain size of the first plurality of solid electrolyte buffer particles is smaller than an average particle size of the first plurality of active material particles. 
     
     
         13 . The solid-state electrochemical cell of  claim 8 , wherein the first electrode is a cathode, and wherein the first plurality of active material particles comprise a lithiated transition metal oxide. 
     
     
         14 . The solid-state electrochemical cell of  claim 8 , wherein the first electrode is an anode, and wherein the first plurality of active material particles comprise silicon, silicon oxide, or graphite. 
     
     
         15 . A method of manufacturing a cathode for a solid-state electrochemical cell, the method comprising:
 depositing a first electrically conductive cathode composite slurry layer including a plurality of first cathode active material particles, a first plurality of solid electrolyte buffer particles comprising sulfide ceramics, and a first binder material onto an aluminum substrate;   depositing a second electrically non-conductive separator slurry layer including a second plurality of solid electrolyte buffer particles comprising sulfide ceramics and a second binder material onto the first electrically conductive cathode composite slurry layer; and   forming interpenetrating fingers between the first electrically conductive cathode composite layer and the second electrically non-conductive separator slurry layer.   
     
     
         16 . The method of  claim 15 , further comprising drying a solvent of the first electrically conductive cathode composite slurry layer and the second electrically non-conductive separator slurry layer. 
     
     
         17 . The method of  claim 15 , further comprising hot compressing the cathode. 
     
     
         18 . The method of  claim 17 , wherein the cathode is hot compressed at a temperature no greater than 600° C. 
     
     
         19 . The method of  claim 15 , wherein the interpenetrating fingers have a length of at least twice an average diameter of the second plurality of solid electrolyte buffer particles. 
     
     
         20 . (canceled) 
     
     
         21 . The method of  claim 15 , wherein the first electrically conductive cathode composite slurry layer further comprises a plurality of conductive additive particles intermixed with the plurality of first cathode active material particles. 
     
     
         22 . The solid-state electrochemical cell of  claim 8 , further comprising:
 a second electrode;   wherein the first electrode is a cathode, the second electrode is an anode, and the current collector comprises an aluminum current collector.   
     
     
         23 . The solid-state electrochemical cell of  claim 22 , wherein the first and second pluralities of solid electrolyte buffer particles each comprise a sulfide ceramic. 
     
     
         24 . The solid-state electrochemical cell of  claim 22 , wherein the first electrically conductive electrode layer includes at least one polymeric binder. 
     
     
         25 . The solid-state electrochemical cell of  claim 22 , wherein an average grain size of the first plurality of solid electrolyte buffer particles is smaller than an average particle size of the first plurality of active material particles. 
     
     
         26 . The solid-state electrochemical cell of  claim 22 , wherein the first plurality of active material particles comprises a lithiated transition metal oxide. 
     
     
         27 . The solid-state electrochemical cell of  claim 22 , wherein the second electrode comprises lithium metal. 
     
     
         28 . The solid-state electrochemical cell of  claim 27 , wherein the second electrode comprises a metallic lithium foil.