A thin battery is produced on a surface is taught. A first electrode layer and a second electrode layer are provided on the surface. An electrolyte layer is printed on the first electrode layer and the second electrode layer. The electrolyte layer possesses substantial mechanical strength such that further printings on top of the electrolyte layer can be done. A photopolymerizable protection layer is printed on the electrolyte layer and around a perimeter of the electrolyte layer, wherein the photopolymerizable protection layer solidifies on exposure to suitable radiation. The electrolyte layer comprises at least one first functional group and the photopolymerizable protection layer comprise at least one second functional group such that on exposure to the suitable radiation some of the at least one first functional group makes chemical bonds with some of the at least one second functional group.

A LiBH.sub.4C.sub.60 nanocomposite that displays fast lithium ionic conduction in the solid state is provided. The material is a homogenous nanocomposite that contains both LiBH.sub.4 and a hydrogenated fullerene species. In the presence of C.sub.60, the lithium ion mobility of LiBH.sub.4 is significantly enhanced in the as prepared state when compared to pure LiBH.sub.4. After the material is annealed the lithium ion mobility is further enhanced. Constant current cycling demonstrated that the material is stable in the presence of metallic lithium electrodes. The material can serve as a solid state electrolyte in a solid-state lithium ion battery.

A method for production of a thin-film battery includes providing a mount structure, applying of a first unmasked flow of a first electrode material to the mount structure in order to form a first electrode layer, applying a second unmasked flow of a battery material in order to form a battery layer, and applying a third unmasked flow of a second electrode material in order to form a second electrode layer. The applying steps are repeated in order to produce a thin-film battery which consists of a plurality of first electrode layers, a plurality of battery layers, and a plurality of second electrode layers.

A method of manufacturing an all-solid-state battery and an apparatus for manufacturing the same are provided. The method of manufacturing the all-solid-state battery includes: (a) a step of forming a non-woven fabric having a fiber made of a resin; (b) a step of applying a slurry containing solid electrolyte particles onto the non-woven fabric; (c) a step of drying the slurry on the non-woven fabric by a heater; (d) a step of pressurizing the slurry on the non-woven fabric by a roller; (e) a step of forming a positive electrode member on one surface of the solid electrolyte membrane; and (f) a step of forming a negative electrode member on the other surface of the solid electrolyte membrane. The step (a) is a step of forming the non-woven fabric by making a resin containing a polar filler fibrous by a laser electrospinning method. By such a method, the all-solid-state battery (a laminated body of a positive electrode member, a solid electrolyte membrane, and a negative electrode member) can be efficiently manufactured.

In accordance with the present invention, deposition of LiCoO.sub.2 layers in a pulsed-dc physical vapor deposition process is presented. Such a deposition can provide a low-temperature, high deposition rate deposition of a crystalline layer of LiCoO.sub.2 with a desired <101> or <003> orientation. Some embodiments of the deposition address the need for high rate deposition of LiCoO.sub.2 films, which can be utilized as the cathode layer in a solid state rechargeable Li battery. Embodiments of the process according to the present invention can eliminate the high temperature (>700 C.) anneal step that is conventionally needed to crystallize the LiCoO.sub.2 layer.

A method is provided for making a ceramic lithium ion conducting membrane and for making an anode pouch for a lithium-seawater battery. The method for making the ceramic membrane includes adding pore formers into a liquid slurry of LTAP (Li.sub.2OAl.sub.2O.sub.3SiO.sub.2P.sub.2O.sub.5TiO.sub.2) powder. The liquid slurry is converted into porous green tape and the porous green tape is laminated onto the top of nonporous green tapes to form a stack. The stack is sintered and the pore formers are decomposed to create pores in the top layer of the ceramic membrane. The porous ceramic membrane is used to create a more robust hermetic seal in an anode pouch for the battery compared to a seal made with a nonporous ceramic membrane.

Elements of an electrochemical cell using an end to end process. The method includes depositing a planarization layer, which manufactures embedded conductors of said cell, allowing a deposited termination of optimized electrical performance and energy density. The present invention covers the technique of embedding the conductors and active layers in a planarized matrix of PML or other material, cutting them into discrete batteries, etching the planarization material to expose the current collectors and terminating them in a post vacuum deposition step.

Approaches herein provide encapsulation of a micro battery cell of a cell matrix. The micro battery cell includes an active device, such as a thin film device, formed atop a first side of a substrate. An encapsulant may be formed over the active device, wherein the encapsulant adheres to the active device and to a second side of the substrate. In some approaches, the encapsulant penetrates a plurality of openings provided through the substrate, thus allowing the encapsulant to form along the second side of the substrate to fully envelope the micro battery cell.

A thin film device. The thin film device may include: an active device region, the active device region comprising a diffusant; and a thin film encapsulant disposed adjacent to the active device region and encapsulating at least a portion of the active device region, the thin film encapsulant comprising: a first layer, the first layer disposed immediately adjacent the active device region and comprising a soft and pliable material; and a second layer disposed on the first layer, the second layer comprising a rigid dielectric material or rigid metal material.

A thin film device. The thin film device may include: an active device region, the active device region comprising a diffusant; and a thin film encapsulant disposed adjacent to the active device region and encapsulating at least a portion of the active device region, the thin film encapsulant comprising: a first layer, the first layer disposed immediately adjacent the active device region and comprising a soft and pliable material; and a second layer disposed on the first layer, the second layer comprising a rigid dielectric material or rigid metal material.