Method of manufacturing an electrode-electrolyte laminate

A method of manufacturing an electrode-electrolyte laminate 1 for use in a lithium-metal cell involves depositing a ceramic electrolyte layer 12 onto a first surface of a sacrificial polymer substrate 11; and depositing a layer of lithium metal 13 onto an exposed surface of the ceramic electrolyte layer to form a laminate precursor. The sacrificial polymer substrate is removed from the laminate precursor to form the electrode-electrolyte laminate. An encapsulation layer 14 may be deposited onto the exposed surface of the layer of lithium metal before the removal of the polymer substrate. The polymer substrate may be removed by being dissolved in a solvent, for example the substrate may be soaked in a solvent and any residual polymer substrate may be removed by rinsing.The ceramic electrolyte layer may comprise LiPON. One or both of the deposition processes may involve the gradual deposition of atoms or molecules, for example PVD methods may be used. Vacuum conditions may be maintained between the deposition of the ceramic electrolyte layer and the deposition of the lithium metal. The polymer substrate may comprise or consist of polystyrene. A cathode layer may comprise a gel cathode 16 or a solvent-cast cathode layer 15.