Layered Cavity Electrode Lithium Battery

Abstract

A battery with many cavities that form tiny reaction zones having voids. A concave-shaped anode and convex shaped cathode is inserted into each of the cavities as layers. During charging, lithium metal forms in each cavity on the anode current collector. The formation of lithium metal in each of the many thousands of small cavities that are isolated from each other prevents the buildup of significant quantities of lithium metal in one location. The combination of tiny reaction zones and voids allows lithium metal to form without stressing the structure of the battery cell.

What is claimed is: 
     
         1 . A battery comprising:
 an array of cavities formed in a continuous non-conductive polymer material;   each said cavity is 1 to 50 microns wide;   a concave-shaped anode in each of said cavities; and   a convex shaped cathode inserted into each of said cavities.   
     
     
         2 . The battery of  claim 1  further comprising:
 some of said cavities are punctured. 
 
     
     
         3 . The battery of  claim 1  further comprising:
 a layer of anode liquid electrolyte; 
 a layer of solid electrolyte; and 
 a void between the said anode liquid electrolyte and said solid electrolyte. 
 
     
     
         4 . The battery of  claim 1  further comprising:
 each said cavity having a lip; 
 each said cavity having an anode current collector; 
 a layer of insulating material on said anode current collector at the said lip of each said cavity. 
 
     
     
         5 . The battery of  claim 1  further comprising:
 the convex shaped cathode having a cathode active mass; and 
 a top non-conductive polymer layer.