Solid-State Battery Electrodes

• US 20140099538A1
• Filed: 03/14/2013
• Published: 04/10/2014
• Est. Priority Date: 10/09/2012
• Status: Active Grant

• Current Assignee: Johnson Ip Holding Llc
• Original Assignee: Microsoft Corporation
• Inventors: Johnson, Lonnie G., Johnson, David K.
• Granted Patent: US 9,793,525 B2
• Time in Patent Office: Days
• US Class Current: 429/211
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0562 Solid materials
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 2300/0068 inorganic
• CPC Class Codes: H01M 2300/0091 in the form of mixtures
• CPC Class Codes: H01M 4/0411 by extrusion
• CPC Class Codes: H01M 4/043 involving compressing or compaction
• 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 4/139 Processes of manufacture
• CPC Class Codes: H01M 4/1395 of electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/405 Alloys based on lithium
• CPC Class Codes: H01M 4/621 Binders
• CPC Class Codes: H01M 50/434 Ceramics
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• 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
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

Embodiments of solid-state batteries, battery components, and related construction methods are described. The components include one or more embodiments of a low melt temperature electrolyte bonded solid-state rechargeable battery electrode and one or more embodiments of a composite separator having a low melt temperature electrolyte component. Embodiments of methods for fabrication of solid-state batteries and battery components are described. These methods include co-extrusion, hot pressing and roll casting.

Claims

1. An electrode of a rechargeable solid-state battery, the electrode comprising:

electrochemically active powder material; and

meltable inorganic solid electrolyte configured to bond the electrochemically active powder material together.

2. The electrode of claim 1, further comprising:

electrolyte powder material having high ion conductivity;

electrically conductive material; and

the meltable inorganic solid electrolyte configured to further bond the electrochemically active powder material, the electrolyte powder and the electrically conductive material together.

3. The electrode of claim 2, wherein the electrolyte powder material having a high ion conductivity is a lithium ion conductive electrolyte powder.

4. The electrode of claim 1, wherein the electrochemically active powder material is lithium-based.

5. The electrode of claim 1, wherein the inorganic solid electrolyte is meltable at a maximum reaction temperature of 500°

C.

6. The electrode of claim 1, wherein the electrode is formed by roll casting a slurry containing the electrochemically active powder material and the meltable inorganic solid electrolyte.

7. The electrode of claim 1, wherein the electrode is formed by hot pressing the electrochemically active powder material and the meltable inorganic solid electrolyte.

8. A solid-state battery comprising:

a metal foil anode substrate; and

an anode-separator casting that includes a separator that is roll cast on the metal foil anode substrate.

9. The solid-state battery of claim 8, further comprising a cathode that is roll cast on the anode-separator casting to form an anode-separator-cathode stack.

10. The solid-state battery of claim 9, further comprising a cathode current collector that is hot press rolled on the anode-separator-cathode stack.

11. The solid-state battery of claim 8, wherein the roll casting comprises:

applying the separator slurry to the metal foil anode substrate;

controlling the thickness of the applied separator slurry with a doctor blade;

drying the separator slurry in a drying oven; and

bonding the dried separator slurry to the metal foil anode substrate with hot press rollers.

12. The solid-state battery of claim 8, further comprising a cathode current collector foil.

13. The solid-state battery of claim 12, wherein the cathode current collector foil is bound to the anode-separator-cathode stack by hot rolling to form a cell.

14. The solid-state battery of claim 8, wherein metal foil anode substrate is a lithium magnesium alloy.

15. An anode of a solid state battery, the anode comprising:

lithium active powder material; and

meltable temperature inorganic solid electrolyte configured to form a protective coating on individual particles of the lithium active powder material.

16. The anode of claim 15, wherein the anode is formed by roll casting.

17. The anode of claim 16, wherein roll casting the anode comprises:

applying the anode slurry to the cathode separator casting;

controlling the thickness of the applied anode slurry with a doctor blade;

drying the anode slurry in a drying oven; and

bonding the dried anode slurry to the cathode separator casting with hot press rollers.

18. The anode of claim 15, wherein the inorganic solid electrolyte is meltable at a maximum reaction temperature of about 500°

C.

19. The anode of claim 15, wherein the anode is formed by hot pressing the lithium active powder material and the inorganic solid electrolyte.

20. The anode of claim 15, wherein the anode is formed by co-extrusion of anode material with cathode material and separator material.