Patent ID: 8114171

Claim:
A method of fabricating an electrochemical device component, the method comprising: forming a laminate of an active metal anode, a first material layer adjacent to the active metal anode that is ionically conductive and chemically compatible with an active metal, wherein the first material layer is selected from the group consisting of a composite reaction product of the active metal with silicon nitride, a composite reaction product of the active metal with a metal halide, a composite reaction product of the active metal with a metal phosphide, a reaction product of the active metal with red phosphorus, a reaction product of the active metal with a wetting layer coated on LiPON, and reaction product of the active metal with a polymer-halide complex, and a second material layer adjacent to the first material layer that is impervious, ionically conductive and chemically compatible with the first material layer, wherein the second material layer is selected from the group consisting of glassy or amorphous metal ion conductors, ceramic active metal ion conductors, and glass-ceramic active metal ion conductors; wherein the forming of the laminate comprises: providing as a substrate the second material layer; forming on the substrate the precursor for the first material layer; and applying the active metal anode to the precursor for the first material layer on the substrate thereby forming the first material layer between the active metal anode and the second material layer; wherein the ionic conductivity of the composite is at least 10 −7 S/cm.