Hybrid electrode and surface-mediated cell-based super-hybrid energy storage device containing same

• US 20130171502A1
• Filed: 12/29/2011
• Published: 07/04/2013
• Est. Priority Date: 12/29/2011
• Status: Active Application

• Current Assignee: Global Graphene Group, Inc.
• Original Assignee: Global Graphene Group, Inc.
• Inventors: Chen, Guorong, Zhamu, Aruna, Wang, Xiqing, Jang, Bor Z., Wang, Yanbo
• Application Number:
  US13/374,408
• Publication Number:
  US 20130171502A1
• Time in Patent Office: Days
• US Class Current: 429/149
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: H01G 11/06 with one of the electrodes allowing ions to be reversibly doped thereinto, e.g. lithium ion capacitors [LIC]
• CPC Class Codes: H01G 11/24 characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosity; characterised by the structural features of powders or particles used therefor
• CPC Class Codes: H01G 11/28 arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
• CPC Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01G 11/46 Metal oxides
• CPC Class Codes: H01G 11/48 Conductive polymers
• CPC Class Codes: H01G 11/86 specially adapted for electrodes carbonisation or activation of carbon for the manufacture of electrodes H01G11/34
• CPC Class Codes: H01M 10/05 Accumulators with non-aqueous electrolyte H01M10/39 takes precedence
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 4/13 Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• 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 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/137 Electrodes based on electro-active polymers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

The present invention provides a multi-component hybrid electrode for use in an electrochemical super-hybrid energy storage device. The hybrid electrode contains at least a current collector, at least an intercalation electrode active material storing lithium inside interior or bulk thereof, and at least an intercalation-free electrode active material having a specific surface area no less than 100 m²/g and storing lithium on a surface thereof, wherein the intercalation electrode active material and the intercalation-free electrode active material are in electronic contact with the current collector. The resulting super-hybrid cell exhibits exceptional high power and high energy density, and long-term cycling stability that cannot be achieved with conventional supercapacitors, lithium-ion capacitors, lithium-ion batteries, and lithium metal secondary batteries.

Claims

1. A multi-component hybrid electrode for use in an electrochemical super-hybrid energy storage device, said hybrid electrode containing at least a current collector, at least an intercalation electrode active material storing lithium inside interior or bulk thereof, and at least an intercalation-free electrode active material having a specific surface area no less than 100 m²/g and storing lithium on a surface thereof, wherein the intercalation electrode active material and the intercalation-free electrode active material are in electronic contact with said current collector.

2. The multi-component hybrid electrode of claim 1, wherein said intercalation electrode active material and said intercalation-free electrode active material form two separate discrete layers that are either (a) respectively bonded to two opposing surfaces of said current collector to form a laminated three-layer electrode or (b) stacked together having one layer bonded to a surface of said current collector to form a laminated electrode.

3. The multi-component hybrid electrode of claim 2, wherein said current collector is porous to enable passage of lithium ions.

4. The multi-component hybrid electrode of claim 1, wherein said intercalation electrode active material and said intercalation-free electrode active material are mixed to form a hybrid active material coated onto one surface or two opposing surfaces of said current collector.

5. The multi-component hybrid electrode of claim 4, wherein said current collector is porous to facilitate lithium ion passage.

6. The multi-component hybrid electrode of claim 1, having at least two current collectors internally connected in parallel, wherein said intercalation electrode active material is coated on at least a surface of a first current collector and said intercalation-free electrode active material is coated on at least a surface of a second current collector.

7. The multi-component hybrid electrode of claim 1, wherein said hybrid electrode is pre-lithiated, having lithium inserted into interior of said intercalation electrode active material and/or having lithium deposited on a surface of said intercalation-free electrode active material.

8. The multi-component hybrid electrode of claim 1, wherein said intercalation electrode active material has a specific surface area less than 100 m²/g.

9. The multi-component hybrid electrode of claim 1, wherein said intercalation electrode active material has a specific surface area less than 100 m²/g and said intercalation-free electrode active material has a specific surface area no less than 500 m²/g.

10. The multi-component hybrid electrode of claim 1, wherein said intercalation electrode active material has a specific surface area less than 50 m²/g and said intercalation-free electrode active material has a specific surface area no less than 1,500 m²/g.

11. The multi-component hybrid electrode of claim 1, wherein said intercalation material is an anode active material selected from the following:

(h) a graphite or carbonaceous intercalation compound having a specific surface area less than 100 m²/g when formed into an anode, said intercalation compound is selected from natural graphite, synthetic graphite, meso-phase carbon, soft carbon, hard carbon, amorphous carbon, polymeric carbon, coke, meso-porous carbon, carbon fiber, graphite fiber, carbon nano-fiber, carbon nano-tube, and expanded graphite platelets or nano graphene platelets containing multiple graphene planes bonded together;

(a) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), and cadmium (Cd);

(b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, or Cd with other elements, wherein said alloys or compounds are stoichiometric or non-stoichiometric;

(c) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Mn, Fe, or Cd, and their mixtures, composites, or lithium-containing composites, including Co₃O₄, Mn₃O₄, and their mixtures or composites;

(d) salts and hydroxides of Sn;

(e) lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxide;

or

(f) a combination thereof.

12. The multi-component hybrid electrode of claim 1, wherein said intercalation material is a cathode active material capable of storing lithium in interior or bulk of said material, selected from the group consisting of lithium cobalt oxide, cobalt oxide, lithium nickel oxide, nickel oxide, lithium manganese oxide, vanadium oxide V₂O₅, V₃O₈, lithium transition metal oxide, lithiated oxide of transition metal mixture, non-lithiated oxide of a transition metal, non-lithiated oxide of transition metal mixture, lithium iron phosphate, lithium vanadium phosphate, lithium manganese phosphate, a non-lithiated transition metal phosphate, a chalcogen compound, sulfur, sulfur-containing molecule, sulfur-containing compound, sulfur-carbon polymer, sulfur dioxide, thionyl chloride (SOCl₂), oxychloride, manganese dioxide, carbon monofluoride ((CF)_n), iron disulfide, copper oxide, lithium copper oxyphosphate (Cu₄O(PO₄)₂), silver vanadium oxide, MoS₂, TiS₂, NbSe₃, and combinations thereof.

13. The multi-component hybrid electrode of claim 12, wherein said intercalation material is in a form of nano-scaled particle, wire, rod, tube, ribbon, sheet, film, or coating having a dimension less than 100 nm.

14. The multi-component hybrid electrode of claim 12, wherein said intercalation material is in a form of nano-scaled particle, wire, rod, tube, ribbon, sheet, film, or coating having a dimension less than 20 nm.

15. The multi-component hybrid electrode of claim 1, wherein said intercalation-free electrode material is a cathode active material that forms a porous structure having a specific surface area no less than 100 m²/g and is selected from:

(a) a porous disordered carbon material selected from activated soft carbon, activated hard carbon, activated polymeric carbon or carbonized resin, activated meso-phase carbon, activated coke, activated carbonized pitch, activated carbon black, activated carbon, or activated partially graphitized carbon;

(b) a graphene material selected from a single-layer graphene, multi-layer graphene, graphene oxide, graphene fluoride, hydrogenated graphene, nitrogenated graphene, boron-doped graphene, nitrogen-doped graphene, functionalized graphene, or reduced graphene oxide;

(c) a meso-porous exfoliated graphite;

(d) a meso-porous carbon;

(e) a carbon nanotube (CNT) selected from a single-walled carbon nanotube or multi-walled carbon nanotube, oxidized CNT, fluorinated CNT, hydrogenated CNT, nitrogenated CNT, boron-doped CNT, nitrogen-doped CNT, or doped CNT;

(f) a carbon nano-fiber, or

(g) a combination thereof.

16. The multi-component hybrid electrode of claim 1, wherein said intercalation-free electrode material is an anode active material that forms a porous structure having a specific surface area no less than 100 m²/g and is selected from:

(a) a porous disordered carbon material selected from activated soft carbon, activated hard carbon, activated polymeric carbon or carbonized resin, activated meso-phase carbon, activated coke, activated carbonized pitch, activated carbon black, activated carbon, or activated partially graphitized carbon;

(b) a graphene material selected from a single-layer graphene, multi-layer graphene, graphene oxide, graphene fluoride, hydrogenated graphene, nitrogenated graphene, boron-doped graphene, nitrogen-doped graphene, functionalized graphene, or reduced graphene oxide;

(c) a meso-porous exfoliated graphite;

(d) a meso-porous carbon;

(e) a carbon nanotube selected from a single-walled carbon nanotube or multi-walled carbon nanotube;

(f) a carbon nano-fiber, or

(g) a combination thereof.

17. A super-hybrid energy storage device comprising a hybrid electrode of claim 1 as a first electrode, a second electrode, a separator disposed between said first and second electrodes, and electrolyte in ionic contact with said electrodes, wherein at least one of said electrodes is provided with a lithium source or pre-loaded with lithium.

18. The super-hybrid energy storage device claim 17, wherein said hybrid electrode is an anode and said second electrode is a cathode formed of a porous cathode active material having a specific surface area no less than 100 m²/g in direct contact with electrolyte, wherein said device operates on an exchange of lithium ions between a surface and/or interior of an anode active material and a surface of said cathode active material.

19. A super-hybrid energy storage device of claim 17, wherein said hybrid electrode is a cathode and said device operates on an exchange of lithium ions between a surface and/or interior of a cathode active material and a surface of said anode.

20. A super-hybrid energy storage device of claim 17, wherein said second electrode is an anode having a current collector and an anode active material and said hybrid electrode is a cathode, and wherein said device operates on an exchange of lithium ions between a surface and/or interior of a cathode active material and a surface of said anode current collector or a surface or interior of said anode active material.

21. A super-hybrid energy storage device of claim 17, wherein said first electrode is a hybrid anode, and said second electrode is a hybrid cathode, wherein said device operates on an exchange of lithium ions between a surface and/or interior of a cathode active material and a surface and/or interior of an anode active material.

22. A super-hybrid energy storage device, comprising:

(A) a first anode being formed of a first anode current collector having a surface area to capture or store lithium thereon;

(B) a first hybrid electrode of claim 1 as a cathode comprising a first cathode current collector and a first intercalation-free cathode active material coated on at least a surface of said first cathode current collector, and a first interaction cathode active material coated on a surface of a second cathode current collector, wherein said first and second cathode current collectors are internally connected in parallel;

(C) a first porous separator disposed between the first hybrid cathode and the first anode;

(D) a lithium-containing electrolyte in physical contact with said first hybrid cathode and first anode; and

(E) at least a lithium source implemented at or near at least one of the anodes or cathodes prior to a first charge or a first discharge cycle of the energy storage device;

wherein said first intercalation-free cathode active material has a specific surface area of no less than 100 m²/g being in direct physical contact with said electrolyte to receive lithium ions therefrom or to provide lithium ions thereto.

23. A super-hybrid energy storage device containing a hybrid electrode of claim 6 as an anode or cathode, at least a counter electrode, a separator separating an anode from a cathode, electrolyte in ionic contact with all electrodes, and a lithium source disposed at an electrode.

24. The super-hybrid energy storage device of claim 22, further comprising a second anode being formed of a second anode current collector having a surface area to capture or store lithium thereon.

25. The super-hybrid energy storage device of claim 22, wherein said first anode contains an anode active material having a specific surface area greater than 100 m²/g.

26. The super-hybrid energy storage device of claim 24, wherein said first anode current collector and said second anode current collector are connected to an anode terminal, and said first cathode current collector and said second cathode current collector are connected to a cathode terminal.

27. The super-hybrid energy storage device of claim 22, wherein at least one of the anode current collectors or cathode current collectors is a porous, electrically conductive material selected from metal foam, metal web or screen, perforated metal sheet, metal fiber mat, metal nanowire mat, porous conductive polymer film, conductive polymer nano-fiber mat or paper, conductive polymer foam, carbon foam, carbon aerogel, carbon xerox gel, graphene foam, graphene oxide foam, reduced graphene oxide foam, carbon fiber paper, graphene paper, graphene oxide paper, reduced graphene oxide paper, carbon nano-fiber paper, carbon nano-tube paper, or a combination thereof.

28. The super-hybrid energy storage device of claim 17, wherein the lithium source comprises a lithium chip, lithium foil, lithium powder, surface stabilized lithium particles, lithium film coated on a surface of an anode or cathode current collector, lithium film coated on a surface of a cathode active material, or a combination thereof.

29. The super-hybrid energy storage device of claim 17, wherein a charge or discharge operation of said device involves both lithium intercalation and lithium deposition on an electrode surface.

30. The super-hybrid energy storage device of claim 17, wherein the electrolyte is liquid electrolyte or gel electrolyte containing a first amount of lithium ions dissolved therein.

31. The super-hybrid energy storage device of claim 30, wherein an operation of said device involves an exchange of a second amount of lithium ions between a cathode and an anode, and said second amount of lithium is greater than said first amount.

32. The super-hybrid energy storage device of claim 17, wherein said lithium source is selected from lithium metal, a lithium metal alloy, a mixture of lithium metal or lithium alloy with a lithium intercalation compound, a lithiated compound, or a combination thereof.

33. The super-hybrid energy storage device of claim 17 wherein said electrolyte comprises a lithium salt-doped ionic liquid, a liquid organic solvent, or a gel electrolyte.

34. The super-hybrid energy storage device of claim 17, which is internally connected to an electrochemical energy storage device in parallel, wherein said electrochemical energy storage device is selected from a supercapacitor, a lithium-ion capacitor, a lithium-ion battery, a lithium metal secondary battery, a lithium-sulfur cell, a surface-mediated cell, or a super-hybrid cell, and wherein an anode of said super-hybrid cell and an anode of said electrochemical cell are internally connected in parallel and a cathode of said super-hybrid cell and a cathode of said electrochemical cell are internally connected in parallel.

35. The super-hybrid energy storage device of claim 17, which is internally connected to an electrochemical energy storage device in series, wherein said electrochemical energy storage device is selected from a supercapacitor, lithium-ion capacitor, lithium-ion battery, lithium metal secondary battery, lithium-sulfur cell, surface-mediated cell, or super-hybrid cell and wherein electrolyte of said super-hybrid cell is not in fluid communication with electrolyte of said electrochemical cell.

36. The super-hybrid energy storage device of claim 17, which is internally connected in series or in parallel to an intercalation or intercalation-free electrode of an electrochemical energy storage device, selected from a supercapacitor, lithium-ion capacitor, lithium-ion battery, lithium metal secondary battery, lithium-sulfur cell, surface-mediated cell, or super-hybrid cell.