MULTILAYER COATINGS FOR RECHARGEABLE BATTERIES

• US 20100291444A1
• Filed: 05/12/2010
• Published: 11/18/2010
• Est. Priority Date: 05/12/2009
• Status: Abandoned Application

• Current Assignee: Lawrence Livermore National Security LLC (Government of the United States of America)
• Original Assignee: Lawrence Livermore National Security LLC (Government of the United States of America)
• Inventors: Farmer, Joseph C., Kaschmitter, James
• Application Number:
  US12/778,975
• Publication Number:
  US 20100291444A1
• Time in Patent Office: Days
• US Class Current: 429/322
• CPC Class Codes: H01M 10/052 Li-accumulators
• 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 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0407 by coating on an electrolyte layer
• CPC Class Codes: H01M 4/621 Binders
• CPC Class Codes: H01M 4/622 being polymers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

A method for producing a rechargeable battery in the form of a multi-layer coating in one embodiment includes applying an active cathode material above an electrically conductive and electrochemically compatible substrate to form a cathode; applying a solid-phase ionically-conductive electrolyte material above the cathode as a second coating to form an electrode separation layer; applying an anode material above the electrode separation layer to form an anode; and applying an electrically conductive overcoat material above the anode. A method for producing a multi-layer coated cell in another embodiment includes applying an anode material above a substrate to form an anode; applying a solid-phase electrolyte material above the anode to form an electrode separation layer; applying an active cathode material above the electrode separation layer to form a cathode; and applying an electrically conductive overcoat material above the cathode. Cells are also disclosed.

Claims

1. A method for producing a rechargeable battery in the form of a multi-layer coating, the method comprising:

applying an active cathode material above an electrically conductive substrate to form a cathode;

applying a solid-phase ionically-conductive electrolyte material above the cathode as a second coating to form an electrode separation layer;

applying an anode material above the electrode separation layer to form an anode; and

applying an electrically conductive overcoat material above the anode.

2. The method of claim 1, wherein the active cathode material includes an ion-conductive polymer as part of a binder phase to facilitate ion transport in interstitial spaces of the cathode, between particles of the active cathode material.

3. The method of claim 1, wherein the anode material includes at least one pure solid-phase element selected from a group consisting of Pb, Cd, Zn, Fe, Na, Ca, Mg, Al, and Li.

4. The method of claim 1, wherein the anode material includes an alloy formed from at least two pure solid-phase elements selected from a group consisting of Pb, Cd, Zn, Fe, Na, Ca, Mg, Al, and Li.

5. The method of claim 1, wherein the anode material includes a hydride.

6. The method of claim 1, wherein the anode includes graphite.

7. The method of claim 1, wherein the anode includes an intercalation compound of lithium.

8. The method of claim 1, wherein the anode includes a lithium-silicon alloy.

9. The method of claim 1, wherein the anode includes a lithium-tin alloy.

10. The method of claim 1, wherein the anode material includes an intercalation compound or alloy of sodium.

11. The method of claim 1, wherein at least one of the anode material, cathode material and electrolyte material includes particles having a shape selected from a group consisting of round, oval, cylindrical, prismatic and irregular shape.

12. The method of claim 2, wherein the ion-conductive polymer in the binder phase comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

13. The method of claim 2, wherein the ion-conductive polymer is combined with conventional binder materials.

14. The method of claim 1, wherein the anode includes an ion-conductive polymer to facilitate transport of cations in interstitial spaces of the anode, between particles of active anode material.

15. The method of claim 14, wherein the ion-conductive polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

16. The method of claim 14, wherein the ion-conductive polymer is used in conjunction with a conventional binder material such as polyvinylidene fluoride (PVDF) to form the binder phase.

17. The method of claim 1, wherein the electrode separation layer comprises hard particles of inorganic solid-state ion conductors dispersed in a polymeric binder, the binder being PVDF, an ion exchange polymer with high ion mobility, a solid polymer electrolyte, or a polymer-gel electrolyte.

18. The method of claim 1, wherein the electrode separation layer comprises hard particles of inorganic solid-state Li-ion conductors dispersed in a polymeric binder, the binder being PVDF, a Li-ion exchange polymer with high Li-ion mobility, a solid polymer electrolyte, or a polymer-gel electrolyte.

19. The method of claim 1, wherein the electrode separation layer comprises hard particles of inorganic solid-state Na-ion conductors dispersed in a polymeric binder, the binder being PVDF, an Na-ion exchange polymer with high Na-ion mobility, a solid polymer electrolyte, or a polymer-gel electrolyte.

20. The method of claim 1, wherein the electrode separation layer comprises hard ceramic particles dispersed in a polymeric binder, the binder being PVDF, an ion exchange polymer with high ion mobility, a solid polymer electrolyte, or a polymer-gel electrolyte.

21. The method of claim 1, wherein the electrode separation layer comprises hard ceramic particles dispersed in a polymeric binder, the binder being an Li-ion exchange polymer with high Li-ion mobility, a solid polymer electrolyte, or a polymer-gel electrolyte.

22. The method of claim 1, wherein the electrode separation layer comprises hard ceramic particles dispersed in a polymeric binder, the binder being an Na-ion exchange polymer with high Na-ion mobility, a solid polymer electrolyte, or a polymer-gel electrolyte, preferred for use with anodes that involve the anodic oxidation of sodium with the formation of sodium ions.

23. The method of claim 17, wherein the ion exchange polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

24. The method of claim 1, wherein the substrate comprises a metal foil.

25. A method for producing a multi-layer coated cell, the method comprising:

applying an anode material above a substrate to form an anode;

applying a solid-phase ionically-conductive electrolyte material above the anode to form an electrode separation layer;

applying an active cathode material above the electrode separation layer to form a cathode; and

applying an electrically conductive overcoat material above the cathode.

26. The method of claim 25, wherein the active cathode material comprises an ionically conductive polymer to facilitate lithium transport in interstitial spaces of the cathode.

27. The method of claim 26, wherein the ionically conductive polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

28. The method of claim 25, wherein cathode comprises polyvinylidene fluoride (PVDF).

29. The method of claim 25, wherein the anode material comprises an ionically conductive polymer to facilitate lithium transport in interstitial spaces of the anode.

30. The method of claim 29, wherein the ionically conductive polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

31. The method of claim 25, wherein the anode comprises polyvinylidene fluoride (PVDF).

32. The method of claim 25, wherein the solid-phase electrolyte material comprises particles of inorganic solid-state lithium ion conductors dispersed in a polymeric binder, the binder being PVDF, an ion exchange polymer with high lithium mobility or a polymeric electrolyte material.

33. The method of claim 32, wherein the ion exchange polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

34. The method of claim 26, wherein the substrate comprises a metal foil.

35. The method of claim 26, wherein at least one of the anode materials includes at a pure solid-phase element selected from a group consisting of Pb, Cd, Zn, Fe, Na, Ca, Mg, Al, Li, and alloys thereof.

36. The method of claim 26, wherein at least one of the anode materials includes a material selected from a group consisting of a hydride, a graphite, an intercalation compound of lithium, a lithium-silicon alloy, a lithium-tin alloy, and an intercalation compound or alloy of sodium.

37. A lithium ion, other rechargeable, or primary cell formed on a single substrate, the cell comprising:

an active cathode material coated onto a substrate;

a solid-phase electrolyte material positioned adjacent to the active cathode material;

an anode material positioned adjacent to the solid-phase electrolyte material; and

an electrically conductive overcoat material positioned adjacent to the anode material.

38. The cell of claim 37, wherein the active cathode material and the anode material comprise an ionically conductive polymer to facilitate lithium transport in interstitial spaces of a cathode and an anode, respectively.

39. The cell of claim 38, wherein the ionically conductive polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

41. The cell of claim 37, wherein the solid-phase electrolyte material comprises particles of inorganic solid-state lithium ion conductors dispersed in a polymeric binder, the binder being PVDF, an ion exchange polymer with high lithium mobility or a polymeric electrolyte material.

42. The cell of claim 41, wherein the ion exchange polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

43. The cell of claim 37, wherein the substrate comprises a metal foil.

44. The cell of claim 37, wherein anode and cathode structures are positioned in a same deposition plane above the substrate and have interdigitated members with the electrolyte material therebetween.

45. The cell of claim 37, wherein at least one of the anode materials includes at a pure solid-phase element selected from a group consisting of Pb, Cd, Zn, Fe, Na, Ca, Mg, Al, Li, and alloys thereof.

46. The cell of claim 37, wherein at least one of the anode materials includes a material selected from a group consisting of a hydride, a graphite, an intercalation compound of lithium, a lithium-silicon alloy, a lithium-tin alloy, and an intercalation compound or alloy of sodium.

47. A lithium ion, other rechargeable, or primary cell formed on a single substrate, the cell comprising:

an anode material coated onto a substrate;

a solid-phase electrolyte material positioned adjacent to the anode material;

an active cathode material positioned adjacent to the solid-phase electrolyte material; and

an electrically conductive overcoat material positioned adjacent to the active cathode material.

40. The cell of claim 47, further comprising polyvinylidene fluoride (PVDF) binding at least one of the anode material and cathode material.

48. The cell of claim 47, wherein the active cathode material and the anode material comprise an ionically conductive polymer to facilitate lithium transport in interstitial spaces of a cathode and an anode, respectively.

49. The cell of claim 48, wherein the ionically conductive polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

50. The cell of claim 47, further comprising polyvinylidene fluoride (PVDF) binding at least one of the anode material and cathode material.

51. The cell of claim 47, wherein the solid-phase electrolyte material comprises particles of inorganic solid-state lithium ion conductors dispersed in a polymeric binder, the binder being PVDF, an ion exchange polymer with high lithium mobility or a polymeric electrolyte material.

52. The cell of claim 51, wherein the ion exchange polymer comprises a polymer with anionic sulfonate groups substituted onto a carbon-based backbone.

53. The cell of claim 47, wherein the substrate comprises a metal foil.

54. The cell of claim 47, wherein anode and cathode structures are positioned in a same deposition plane above the substrate and have interdigitated members with the electrolyte material therebetween.

55. The cell of claim 47, wherein at least one of the anode materials includes at a pure solid-phase element selected from a group consisting of Pb, Cd, Zn, Fe, Na, Ca, Mg, Al, Li, and alloys thereof.

56. The cell of claim 47, wherein at least one of the anode materials includes a material selected from a group consisting of a hydride, a graphite, an intercalation compound of lithium, a lithium-silicon alloy, a lithium-tin alloy, and an intercalation compound or alloy of sodium.