Multi-cell lithium-ion batteries

• US 10,128,536 B2
• Filed: 05/21/2013
• Issued: 11/13/2018
• Est. Priority Date: 05/21/2012
• Status: Active Grant

• Current Assignee: A123 Systems Incorporated
• Original Assignee: A123 Systems Incorporated
• Inventors: Gardner, William H.
• Primary Examiner(s): Gilliam, Barbara L
• Assistant Examiner(s): Zemui, Nathanael T
• Application Number:
  US14/402,676
• Publication Number:
  US 20150155596A1
• Time in Patent Office: 2,002 Days
• CPC Class Codes: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• CPC Class Codes: H01M 10/049 Processes for forming or storing electrodes in the battery container
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/0567 characterised by the additives
• CPC Class Codes: H01M 10/0587 of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
• CPC Class Codes: H01M 10/4235 Safety or regulating additives or arrangements in electrodes, separators or electrolyte H01M10/4242 takes precedence
• CPC Class Codes: H01M 2300/0025 Organic electrolyte
• CPC Class Codes: H01M 4/5825 Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
• CPC Class Codes: H01M 50/529 Intercell connections through partitions, e.g. in a battery casing
• CPC Class Codes: H01M 50/531 Electrode connections inside a battery casing
• CPC Class Codes: H01M 50/533 characterised by the shape of the leads or tabs
• CPC Class Codes: H01M 50/534 characterised by the material of the leads or tabs
• CPC Class Codes: H01M 50/581 in response to temperature
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

Lithium ion (Li-ion) multi-cell batteries in which the requirements for individual monitoring and controlling charging of each cell, the requirements for monitoring and controlling charge balancing and the effects of repeated charging and discharging are ameliorated are presented. In one or more embodiments, the multi-cell battery includes configuration material that substantially provides a moisture barrier.

Claims

1. A battery comprising:

a container having a number of cell cavities;

a number of electrochemical assemblies, each electrochemical assembly enfolded, one of said number of electrochemical assemblies disposed in each one of said number of cell cavities;

wherein each electrochemical assembly comprises a substantially spirally wound electrochemical assembly; and

each one of said number of electrochemical assemblies comprising;

a positive electrode and a negative electrode; and

a separator material between the positive electrode and the negative electrode;

an electrolyte in each cell cavity from said number of cell cavities, said electrolyte comprising a lithium salt and a redox shuttle;

said electrolyte and positive and negative electrodes selected to, during battery operation, provide a predetermined voltage across each electrochemical assembly in each cell cavity;

said redox shuttle being selected to provide shuttle operations when voltage across each electrochemical assembly in each cell cavity reaches another predetermined voltage; and

a cover disposed on said container;

said cover being permanently attached to said container so as to form a hermetic seal between said cover and said container;

said cover forming a seal between each cell cavity;

wherein said substantially spirally wound electrochemical assembly has an inner surface and an outer surface, the inner surface defining a central space;

wherein the outer surface of said substantially spirally wound electrochemical assembly is inclined with respect to a center axis of said substantially spirally wound electrochemical assembly;

inclination constituting a taper, said taper being selected to be equal to a taper of walls of each cell cavity from the number of cell cavities;

wherein said central space is filled with a compliant material, said compliant material having elastic behavior;

wherein said compliant material is a flexible and inert polymer capable of applying a compressive pressure on the substantially spirally wound electrochemical assembly; and

wherein said flexible and inert polymer consists of polyisobutylene.

2. The battery of claim 1, wherein the redox shuttle comprises an aromatic compound having at least one aromatic ring with four or more electronegative substituents, two or more oxygen atoms bonded to said at least one aromatic ring, and no hydrogen atoms bonded to said at least one aromatic ring.

3. The battery of claim 1 further comprising a number of bar connectors securely attached to each positive electrode and to each negative electrode in each electrochemical assembly;

at least one bar connector being securely attached to each positive electrode and at least another one bar connector being securely attached to each negative electrode.

4. The battery of claim 3, wherein at least some of the number of electrochemical assemblies are connected in series;

and wherein the battery comprises at least one bimetallic joint connector connecting the positive electrode in one electrochemical assembly to the negative electrode in another one of said number of electrochemical assemblies in order to connect said one electrochemical assembly in series with said another one of said number of electrochemical assemblies;

wherein one section of said at least one bimetallic joint connector comprises a metal compatible with the positive electrode and another section of said at least one bimetallic joint connector comprises another metal compatible with the negative electrode;

said one section being electrically operatively connected to said another section,

wherein externally exposed surfaces of said at least one bimetallic joint connector are covered with an electrolyte resistant material,

wherein said electrolyte resistant material comprises an electrolyte resistant polymer, and

wherein said electrolyte resistant polymer comprises polypropylene.

5. The battery of claim 1, wherein said container comprises a layer of conductive material providing a barrier to moisture and vapors;

and wherein the layer of conductive material is on each of three sides of a container cell.

6. The battery of claim 5, wherein said layer of conductive material is embedded within walls of said container.

7. The battery of claim 5, wherein said layer of conductive material is disposed on external surfaces of said container.

8. The battery of claim 5, wherein said layer of conductive material is disposed on internal surfaces of said container.

9. The battery of claim 5, further comprising a desiccant component disposed inside each cell cavity.

10. The battery of claim 1, wherein said cover comprises a conductive material layer disposed on an internal surface of said cover;

said conductive material layer providing a moisture barrier.

11. The battery of claim 1, wherein at least some electrochemical assemblies from the number of electrochemical assemblies are connected in series;

and wherein the battery comprises at least one bimetallic joint connector connecting the positive electrode in one electrochemical assembly to the negative electrode in another electrochemical assembly in order to connect said one electrochemical assembly in series with said another electrochemical assembly;

wherein one section of said at least one bimetallic joint connector comprises a metal compatible with the positive electrode and another section of said at least one bimetallic joint connector comprises another metal compatible with the negative electrode;

said one section being electrically operatively connected to said another section;

externally exposed surfaces of said at least one bimetallic joint connector being covered with an electrolyte resistant material;

said container comprising a layer of conducting material providing a barrier to moisture and vapors; and

said cover comprising a conducting material layer disposed on an internal surface of said cover;

said conducting material layer providing a moisture barrier; and

wherein each electrochemical assembly is connected in series with another one of said number of electrochemical assemblies.

12. The battery of claim 11, wherein the positive electrode in each electrochemical assembly comprises an olivine compound having a composition Li_xM′

_yM″

_a(PO₄), and a predetermined surface area, wherein M′

is at least iron, M″

is a first row transition metal selected from Ti, V, Cr, Mn, Co, and Ni, x is equal to or greater than 0, and a and y are greater than 0.

13. The battery of claim 11, wherein the positive electrode in each electrochemical assembly comprises a lithium transition metal phosphate material having a predetermined specific surface area and including only one transition metal, the lithium transition metal phosphate material and the surface area selected to provide at least two co-existing olivine phases during cycling of the battery, wherein the two co-existing olivine phases include a lithium-rich transition metal phosphate phase and a lithium-poor transition metal phosphate phase, wherein a percentage molar volume difference between the two phases is less than about 6.4%, and

wherein the predetermined specific surface area is at least about 20 m²/g.

14. The battery of claim 1, wherein the positive electrode in each electrochemical assembly comprises an olivine compound having a composition Li_xM′

_yM″

(PO₄), and a predetermined surface area, wherein M′

is at least iron, M″

is a first row transition metal selected from Ti, V, Cr, Mn, Co, and Ni, x is equal to or greater than 0, and a and y are greater than 0.

15. The battery of claim 1, wherein the positive electrode in each electrochemical assembly comprises a lithium transition metal phosphate material having a predetermined specific surface area and including only one transition metal, the lithium transition metal phosphate material and the surface area selected to provide at least two co-existing olivine phases during cycling of the battery, wherein the two co-existing olivine phases include a lithium-rich transition metal phosphate phase and a lithium-poor transition metal phosphate phase, wherein a percentage molar volume difference between the two phases is less than about 6.4%, and

wherein the predetermined specific surface area is at least about 20 m²/g.