BATTERIES AND ELECTRODES FOR USE THEREOF

• US 20090202903A1
• Filed: 11/26/2008
• Published: 08/13/2009
• Est. Priority Date: 05/25/2007
• Status: Abandoned Application

• Current Assignee: Massachusetts Institute of Technology
• Original Assignee: Massachusetts Institute of Technology
• Inventors: Chiang, Yet-Ming, Chin, Timothy E., Lai, Wei, Erdonmez, Can K., Wartena, Ryan C.
• Application Number:
  US12/323,983
• Publication Number:
  US 20090202903A1
• Time in Patent Office: Days
• US Class Current: 429/203
• 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 10/0562 Solid materials
• CPC Class Codes: H01M 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 4/0426 Sputtering
• CPC Class Codes: H01M 4/0471 involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1391 of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1393 of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/1397 of electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
• CPC Class Codes: H01M 4/485 of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy H01M4/505, H01M4/525 take precedence
• CPC Class Codes: H01M 4/505 of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
• 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 4/664 Ceramic materials
• CPC Class Codes: H01M 4/667 in the form of layers, e.g. coatings
• 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

Abstract

The present invention generally relates to batteries or other electrochemical devices, and systems and materials for use in these, including novel electrode materials and designs. In some embodiments, the present invention relates to small-scale batteries or microbatteries. For example, in one aspect of the invention, a battery may have a volume of no more than about 5 mm³, while having an energy density of at least about 400 W h/l. In some cases, the battery may include a electrode comprising a porous electroactive compound. In some embodiments, the pores of the porous electrode may be at least partially filled with a liquid such as a liquid electrolyte. The electrode may be able to withstand repeated charging and discharging. In some cases, the electrode may have a plurality of protrusions and/or a wall (which may surround the protrusions, if present); however, in other cases, there may be no protrusions or walls. The electrode may be formed from a unitary material. In certain embodiments, a nonporous electrolyte may be disposed onto the electrode. Such an electrolyte may allow ionic transport (e.g., of lithium ions) while preventing dendritic formation due to the lack of pores. In certain embodiments the porous electrode has a surface that is denser than its interior. Other aspects of the invention are directed to techniques of making such electrodes or batteries, techniques of forming electrical connections to and packaging such batteries, techniques of using such electrodes or batteries, or the like.

Claims

1. An article, comprising:

an electrode formed from a sintered ceramic, the electrode having a porosity of no more than about 50%, at least some of the pores of the electrode being filled with an electrolyte that is a liquid or a polymer.

5. The article of claim 1, wherein the electrode has a linear strain differential of less than about 20% when the electrode is infiltrated with Li ions.

6. The article of claim 1, wherein the electrode has a linear strain differential of less than about 2% when the electrode is infiltrated with Li ions.

8. The article of claim 1, further comprising a nonporous electrolyte disposed on the electrode.

9. The article of claim 1, wherein the porosity is no more than about 30%.

10. The article of claim 9, wherein the porosity is no more than about 20%.

11. The article of claim 10, wherein the porosity is no more than 15%.

12. The article of claim 1, wherein the ceramic comprises LiCoO₂.

14. The article of claim 1, wherein the ceramic comprises Li_x(Ni_a, Co_b, Al_c)O₂, wherein x is between about 0 and about 1.5, and the sum of a, b, and c is about 1.

15. The article of claim 1, wherein the ceramic comprises Li_x(Mn_a, Ni_b, Co_c)O₂, wherein x is between about 0 and about 1.5, and the sum of a, b, and c is about 1.

18. The article of claim 8, wherein the nonporous electrolyte comprises LiPON.

19. The article of claim 1, wherein the article is a battery.

21. The article of claim 19, wherein the battery has a storage density of at least about 400 W h/l.

28. The article of claim 1, wherein the ceramic has a smallest dimension that is at least about 0.2 mm.

29. The article of claim 28, wherein the ceramic has a smallest dimension that is at least about 0.4 mm.

30. The article of claim 29, wherein the ceramic has a smallest dimension that is at least about 0.6 mm.

2-4. -4. (canceled)

7. (canceled)

13. (canceled)

16-17. -17. (canceled)

20. (canceled)

22-27. -27. (canceled)

31-68. -68. (canceled)

69. An article, comprising:

an electrode formed from a sintered ceramic that is able to retain at least about 50% of its initial storage capacity after at least 6 charge-discharge cycles at a C/20 rate.

70-181. -181. (canceled)

182. An article, comprising:

an electrode formed from a sintered ceramic, the electrode having a density of at least about 50%, a thickness of at least about 0.25 mm.

184. The article of claim 182, wherein the electrode has a density of at least about 70%.

185. The article of claim 182, wherein the electrode has a density of at least about 80%.

183. (canceled)

186-197. -197. (canceled)

198. An article, comprising:

an electrode formed from a sintered ceramic, the electrode having a product of density, wherein the density is measured as a percent of the theoretical density of the ceramic, and thickness, wherein the thickness is measured in millimeters, of between about 10%-mm and about 150%-mm.

199-217. -217. (canceled)

218. An article, comprising:

an electrode formed from a sintered ceramic, the electrode having a charge capacity per unit area of electrode of between about 10 mAh/cm² and about 100 mAh/cm².

219-239. -239. (canceled)