Battery including aluminum components

• US 20050112467A1
• Filed: 11/24/2003
• Published: 05/26/2005
• Est. Priority Date: 11/24/2003
• Status: Active Grant

• Current Assignee: Duracell U.S. Operations, Inc. (Berkshire Hathaway Incorporated)
• Original Assignee: Gillette Company (The Procter & Gamble Company)
• Inventors: Berkowitz, Fred J., Issaev, Nikolai N., Pozin, Michael
• Granted Patent: US 7,279,250 B2
• Time in Patent Office: Days
• US Class Current: 429/231.950
• CPC Class Codes: H01M 2004/028 Positive electrodes
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 4/5815 Sulfides
• CPC Class Codes: H01M 4/5825 Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/53135 Storage cell or battery

Abstract

A primary lithium battery can include a current collector that includes aluminum, a cap that includes aluminum, or both. The aluminum battery components can have high mechanical strength and low electrical resistance.

Claims

1. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including aluminum and a cathode active material in contact with the current collector; and

a separator between the anode and the cathode.

2. The battery of claim 1, wherein the lithium-containing anode active material is lithium or a lithium alloy.

3. The battery of claim 1, wherein the current collector includes an aluminum alloy.

4. The battery of claim 1, wherein the current collector includes a 2000 series aluminum alloy, a 6000 series aluminum alloy, or a 7000 series aluminum alloy.

5. The battery of claim 1, wherein the current collector includes a 6000 series aluminum alloy.

6. The battery of claim 1, wherein the current collector includes an aluminum alloy including 0-0.4% by weight of chromium.

7. The battery of claim 1, wherein the current collector includes an aluminum alloy including 0.01-6.8% by weight of copper.

8. The battery of claim 1, wherein the current collector includes an aluminum alloy including 0.05-1.3% by weight of iron.

9. The battery of claim 1, wherein the current collector includes an aluminum alloy including 0.1-7% by weight of magnesium.

10. The battery of claim 1, wherein the current collector includes an aluminum alloy including 0-2% by weight of manganese.

11. The battery of claim 1, wherein the current collector includes an aluminum alloy including 0-2% by weight of silicon.

12. The battery of claim 1, wherein the current collector includes an aluminum alloy including less than 0.25% by weight of titanium.

13. The battery of claim 1, wherein the current collector includes an aluminum alloy including 0-2.3% by weight of nickel.

14. The battery of claim 1, wherein the current collector includes an aluminum alloy including 0-8.2% by weight of zinc.

15. The battery of claim 1, further comprising a nonaqueous electrolyte in contact with the anode, the cathode, and the separator.

16. The battery of claim 15, wherein the nonaqueous electrolyte includes an organic solvent.

17. The battery of claim 15, wherein the nonaqueous electrolyte includes a perchlorate salt.

18. The battery of claim 1, wherein the cathode active material includes a manganese dioxide, a CF_x, iron disulfide, or a vanadate.

19. The battery of claim 1, wherein the current collector is an expanded metal grid.

20. The battery of claim 19, wherein the current collector has a yield strength of at least 2.0 lb/in.

21. The battery of claim 19, wherein the current collector has a yield strength of at least 5 lb/in.

22. The battery of claim 19, wherein the current collector has a tensile strength of at least 5 lb/in.

23. The battery of claim 19, wherein the current collector has a tensile strength of at least 7 lb/in.

24. The battery of claim 19, wherein the current collector has a yield strength of at least 2.0 lb/in and a tensile strength of at least 5 lb/in.

25. The battery of claim 19, wherein the current collector has a yield strength of at least 5 lb/in and a tensile strength of at least 7 lb/in.

26. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including aluminum and a cathode active material in contact with the current collector, wherein the current collector has a resistivity of less than 100 mΩ

/cm; and

a separator between the anode and the cathode.

27. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including aluminum and a cathode active material in contact with the current collector, wherein the current collector has a resistivity of less than 10 mΩ

/cm; and

a separator between the anode and the cathode.

28. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including an aluminum alloy and a cathode active material including a manganese dioxide in contact with the current collector;

a separator between the anode and the cathode; and

a non-aqueous electrolyte including an organic solvent and a perchlorate salt in contact with the anode, the cathode and the separator.

29. The battery of claim 28, wherein the aluminum alloy is a 2000 series. aluminum alloy, a 6000 series aluminum alloy, or a 7000 series aluminum alloy.

30. The battery of claim 28, wherein the aluminum alloy is a 6000 series aluminum alloy.

31. The battery of claim 28, wherein the aluminum alloy including 0-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.05-1.3% by weight of iron, 0.1-7% by weight of magnesium, 0-2% by weight of manganese, 0-2% by weight of silicon, less than 0.25% by weight of titanium, 0-2.3% by weight of nickel, and 0-8.2% by weight of zinc.

32. The battery of claim 28, wherein the current collector is an expanded metal grid.

33. The battery of claim 32, wherein the current collector has a yield strength of at least 2.0 lb/in.

34. The battery of claim 32, wherein the current collector has a yield strength of at least 5 lb/in.

35. The battery of claim 32, wherein the current collector has a tensile strength of at least 5 lb/in.

36. The battery of claim 32, wherein the current collector has a tensile strength of at least 7 lb/in.

37. A method of making a primary lithium battery comprising assembling a solid cathode including a current collector including aluminum, an anode including lithium, and a separator in a housing.

38. The method of claim 37, wherein the current collector includes a 1000 series aluminum, a 2000 series aluminum alloy, a 6000 series aluminum alloy, or a 7000 series aluminum alloy.

39. The method of claim 37, wherein the current collector includes a 6000 series aluminum alloy.

40. The method of claim 37, wherein the current collector is an expanded metal grid.

41. The method of claim 37, wherein the cathode includes a manganese dioxide, a CF_x, iron disulfide, or a vanadate.

42. The method of claim 37, further comprising placing a nonaqueous electrolyte in the housing.

43. The method of claim 42, wherein the nonaqueous electrolyte includes an organic solvent.

44. The method of claim 42, wherein the nonaqueous electrolyte includes a perchlorate salt.

45. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including an aluminum alloy and a cathode active material including manganese dioxide in contact with the current collector;

a separator between the anode and the cathode; and

a non-aqueous electrolyte including an organic solvent and a perchlorate salt in contact with the anode, the cathode and the separator.

46. The battery of claim 45, wherein the aluminum alloy is a 2000 series aluminum alloy, a 6000 series aluminum alloy, or a 7000 series aluminum alloy.

47. The battery of claim 45, wherein the aluminum alloy is a 6000 series aluminum alloy.

48. The battery of claim 45, wherein the aluminum alloy including 0-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.05-1.3% by weight of iron, 0.1-7% by weight of magnesium, 0-2% by weight of manganese, 0-2% by weight of silicon, less than 0.25% by weight of titanium, 0-2.3% by weight of nickel, and 0-8.2% by weight of zinc.

49. The battery of claim 45, wherein the current collector is an expanded metal grid.

50. The battery of claim 49, wherein the current collector has a yield strength of at least 2.0 lb/in.

51. The battery of claim 49, wherein the current collector has a yield strength of at least 5 lb/in.

52. The battery of claim 49, wherein the current collector has a tensile strength of at least 5 lb/in.

53. The battery of claim 49, wherein the current collector has a tensile strength of at least 7 lb/in.

54. The battery of claim 49, wherein the current collector has a yield strength of at least 2.0 lb/in and a tensile strength of at least 5 lb/in.

55. The battery of claim 49, wherein the current collector has a yield strength of at least 2.5 lb/in and a tensile strength of at least 7 lb/in.

56. A primary lithium battery comprising:

an anode including a lithium-containing anode active material; and

a cathode including a current collector including a 6061 aluminum alloy and a cathode active material in contact with the current collector.

57. The battery of claim 56, wherein the cathode active material is a solid.

58. The battery of claim 56, wherein the cathode active material is a liquid.

59. The battery of claim 56, wherein the cathode active material includes SO_{2 or SOCl2}.

60. The battery of claim 56, wherein the current collector includes a pulled grid.

61. The battery of claim 56, wherein the current collector includes a leveled grid.

62. A method of making a primary lithium battery comprising assembling a solid cathode including a current collector including an aluminum alloy, an anode including lithium, and a separator in a housing.

63. The method of claim 62, wherein the current collector includes a 2000 series aluminum alloy, a 6000 series aluminum alloy, or a 7000 series aluminum alloy.

64. The method of claim 62, wherein the current collector includes a 6000 series aluminum alloy.

65. The method of claim 62, wherein the aluminum alloy including 0-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.05-1.3% by weight of iron, 0.1-7% by weight of magnesium, 0-2% by weight of manganese, 0-2% by weight of silicon, less than 0.25% by weight of titanium, 0-2.3% by weight of nickel, and 0-8.2% by weight of zinc.

66. The method of claim 62, wherein the current collector is an expanded metal grid.

67. The method of claim 62, wherein the cathode includes a manganese dioxide, a CF_x, iron disulfide, or a vanadate.

68. The method of claim 62, further comprising placing a nonaqueous electrolyte in the housing.

69. The method of claim 68, wherein the nonaqueous electrolyte includes an organic solvent.

70. The method of claim 68, wherein the nonaqueous electrolyte includes a perchlorate salt.