Electrophoretic assembly of electrochemical devices

• US 20050272214A1
• Filed: 04/18/2005
• Published: 12/08/2005
• Est. Priority Date: 10/20/2000
• Status: Active Grant

• Current Assignee: A123 Systems Incorporated
• Original Assignee: A123 Systems Incorporated, Massachusetts Institute of Technology
• Inventors: Hellweg, Benjamin, Chiang, Yet-Ming, Kim, Dong-Wan, Tobias, Steven M., Wartena, Ryan Craig, Holman, Richard K.
• Granted Patent: US 7,662,265 B2
• Time in Patent Office: Days
• US Class Current: 438/309
• CPC Class Codes: C25D 13/00 Electrophoretic coating characterised by the process C25D15/00 takes precedence; compositions for electrophoretic coating C09D5/44
• CPC Class Codes: C25D 17/00 Constructional parts, or assemblies thereof, of cells for electrolytic coating
• CPC Class Codes: G02F 2001/1555 Counter electrode
• CPC Class Codes: H01G 11/26 characterised by their structure, e.g. multi-layered, porosity or surface features
• CPC Class Codes: H01G 11/56 Solid electrolytes, e.g. gels; Additives therein
• CPC Class Codes: H01G 11/64 characterised by additives
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0472 Vertically superposed cells with vertically disposed plates
• 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 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2004/025 with shapes other than plane or cylindrical
• CPC Class Codes: H01M 4/02 Electrodes composed of, or comprising, active material
• CPC Class Codes: H01M 4/0438 by electrochemical processing electroless electrochemical plating C23C18/54
• CPC Class Codes: H01M 4/0457 from dispersions or suspensions; Electrophoresis
• CPC Class Codes: H01M 4/08 Processes of manufacture
• CPC Class Codes: H01M 4/139 Processes of manufacture
• CPC Class Codes: H01M 4/525 : of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• CPC Class Codes: H01M 4/661 : Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/808 : Foamed, spongy materials
• CPC Class Codes: H01M 6/18 : with solid electrolyte
• CPC Class Codes: H01M 6/181 : with polymeric electrolytes
• CPC Class Codes: H01M 6/40 : Printed batteries , e.g. thin film batteries
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

Methods are provided for making bipolar electrochemical devices, such as batteries, using electrophoresis. A bipolar device is assembled by applying a field that creates a physical separation between two active electrode materials, without requiring insertion of a discrete separator film or electrolyte layer.

Claims

1. A method of assembling a bipolar device including a first terminal and a second terminal comprising:

providing the first terminal;

providing particles of a first electroactive material in a medium;

providing the second terminal electronically connected to a second electroactive material;

generating a field causing particles of the first electroactive material to form an electronically continuous electrode, and creating an electronically insulating separation between the first and second electroactive materials; and

preserving the electronically insulating separation between the first and second electroactive materials.

2. The method of claim 1, comprising generating an electrical field causing particles of the first electroactive material to form an electronically continuous electrode, and creating an electronically insulating separation between the first and second electroactive materials.

3. The method of claim 2, wherein the electrical field is generated by applying an electrical potential between the first terminal and the second terminal.

4. The method of claim 2, wherein the electrical field is generated by applying an electrical potential between one of the first and second terminals and a third terminal.

5. The method of claim 2, wherein the electrical field attracts particles of the first electroactive material to the first terminal.

6. The method of claim 1, further comprising depositing particles of the first electroactive material on the first terminal.

7. The method of claim 2, wherein the electrical field attracts particles of the first electroactive material to the first terminal and repels particles of the first electroactive material from the second electroactive material in the medium.

8. The method of claim 2, wherein the electrical field repels particles of the first electroactive material from the second electroactive material in the medium.

9. The method of claim 1, further comprising providing an ionically conductive material in the electronically insulating separation between the first and second electroactive materials.

10. The method of claim 9, wherein the ionically conductive material is a liquid electrolyte.

11. The method of claim 1, wherein the medium includes a polymer, and wherein preserving the electronically insulating separation between the first and second electroactive materials includes solidifying or drying the polymer to form a solid polymer electrolyte.

12. The method of claim 1, wherein the second electroactive material has a three-dimensional structure defining a void space, and wherein the field causes particles of the first electroactive material to concentrate in the void space.

13. The method of claim 12, wherein the second electroactive material is a porous electrode, and wherein the field causes particles of the first electroactive material to concentrate in the pore space of the porous electrode.

14. The method of claim 13, wherein the porous electrode is a reticulated open-cell carbon, metal or ceramic foam.

15. The method of claim 1, wherein particles of at least one of the first and second electroactive materials are coated with a conductive material.

16. The method of claim 1, wherein at least one of the terminals is patterned to include a serpentine, spiral, or comb-like region and further comprising depositing electroactive material in the region.

17. The method of claim 1, wherein the first and second terminals are constructed and arranged to be interdigitated.

18. The method of claim 1, further comprising depositing particles of the first electroactive material on the first terminal thereby forming an electronically continuous first electrode;

and

generating a second field causing particles of the second electroactive material to deposit on the second terminal, thereby forming an electronically continuous second electrode.

19. The method of claim 18, further comprising creating an electronically insulating separation between the first and second electrodes;

and

preserving the electronically insulating separation between the first and second electrodes.

20. The method of claim 18, wherein the first and second electrodes are formed simultaneously.

21. The method of claim 18, wherein the first and second electrodes are formed sequentially.

22. A bipolar device made by the method of claim 1.

23. A bipolar device made by the method of claim 18.

24. A method of making an electrode comprising:

providing a first terminal;

providing conductive particles of an electroactive material in a medium;

providing a second terminal;

applying an electrical potential between the first and the second terminal to deposit conductive particles of the electroactive material at the first terminal thereby forming an electronically continuous electrode;

forming a continuous bridge of conductive particles of the electroactive material between the first and second terminals; and

removing the applied electrical potential.

25. The method of claim 24, further comprising:

providing a third terminal;

providing conductive particles of a second electroactive material in a medium;

providing a fourth terminal;

applying an electrical potential between the third and the fourth terminals to deposit conductive particles of the second electroactive material at the third terminal thereby forming a second electronically continuous electrode;

forming a second continuous bridge of conductive particles of the second electroactive material between the third and fourth terminals; and

removing the applied electrical potential.

26. An electrode made by the method of claim 24.

27. A battery comprising:

a substrate;

a first terminal;

a second terminal; and

a localized conductive region comprising electroactive material formed on the substrate and surrounded by an insulating region,

wherein at least one of the first or second terminals is electronically connected to the conductive region.

28. The battery of claim 27, wherein the localized conductive region has an area of less than 100 nanometers squared.

29. The battery of claim 27, having a volume of less than 1 cubic millimeter.