Electrode covering for electrochemical cells

• US 5,458,994 A
• Filed: 03/17/1995
• Issued: 10/17/1995
• Est. Priority Date: 06/24/1993
• Status: Expired due to Term

• Current Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Original Assignee: Wilson Greatbatch Technologies, Inc.
• Inventors: Muffoletto, Barry C., Spaulding, Joseph E., Nesselbeck, Neal N.
• Primary Examiner(s): Maples, John S.
• Application Number:
  US08/406,295
• Time in Patent Office: 214 Days
• Field of Search: 429/101, 429/213, 429/191
• US Class Current: 429/101
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 2300/0025 Organic electrolyte
• CPC Class Codes: H01M 2300/0065 Solid electrolytes
• CPC Class Codes: H01M 4/043 involving compressing or compaction
• CPC Class Codes: H01M 4/12 of consumable metal or alloy electrodes use of alloy compositions as active materials H01M4/38
• 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 4/38 of elements or alloys
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/74 Meshes or woven material; Expanded metal
• CPC Class Codes: H01M 4/75 Wires, rods or strips
• CPC Class Codes: H01M 4/762 Porous or perforated metallic containers
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: H01M 6/182 with halogenide as solid electrolyte
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

In an alkali metal-halogen or oxyhalide electrochemical cell wherein an alkali metal anode, preferably lithium, has a surface in operative contact with a halogen-containing or oxyhalide cathode/electrolyte including a solvent if necessary, an electrode covering, preferably applied on the anode surface comprising a non-fabric, continuous and solid film of substrate material having a uniform unit weight, is described. The substrate material is perforated to provide for ion flow therethrough and coated with organic electron donor material, or other suitable coating material. The film substrate material preferably comprises a mechanically perforated synthetic polyester film material, and the film is prepared by contacting with a solution of the organic material and solvent followed by drying. The resulting coated film is flexible and is applied to the operative surface of the electrode thereby covering the same, preferably adhered to the surface by pressing. The flexible film can be applied equally well to electrode surfaces which are either smooth and flat or irregular.

Claims

1. In an electrochemical cell comprising anode and cathode electrodes and an operatively associated electrolyte, the improvement comprising:

a covering at one or more interfaces of the electrodes and the electrolyte, the covering comprising a non-fabric, continuous film of anode ion impermeable substrate material having a uniform unit weight and perforated with a pattern of openings, each opening having a desired shape to provide for anode ion flow therethrough, wherein the substrate material is uniformly coated with an organic electron donor material.

2. The electrochemical cell of claim 1 wherein the organic electron donor material comprises poly-2-vinylpyridine.

3. The electrochemical cell of claim 1 wherein the anode is lithium.

4. The electrochemical cell of claim 1 wherein the substrate is a polyester material.

5. The electrochemical cell of claim 4 wherein the polyester material is polyethylene terephthalate film.

6. The electrochemical cell of claim 1 wherein the pattern of openings provides the continuous film with about a 50% open area.

7. In an alkali metal-halogen electrochemical cell comprising anode and cathode electrodes and an operatively associated electrode, the improvement comprising:

a covering at one or more interfaces of the electrodes and the electrolyte, the covering comprising a non-fabric, continuous film of anode ion impermeable substrate material having a uniform unit weight and perforated with a pattern of openings, each opening having a desired shape to provide for anode ion flow therethrough, wherein the substrate material is uniformly coated with an organic electron donor material.

8. The electrochemical cell of claim 7 wherein the organic election donor material comprises poly-2-vinylpyridine.

9. The electrochemical cell of claim 7 wherein the anode is lithium.

10. The electrochemical cell of claim 8 wherein the substrate material is polyethylene terephthalate.

11. The electrochemical cell of claim 7 wherein the pattern of openings provides the continuous film with about a 50% open area.

12. In an alkali metal-halogen electrochemical cell wherein an alkali metal anode has a surface in contact with a solid electrolyte, the improvement comprising:

a covering at the interface of the electrodes on the anode surface, the covering comprising a non-fabric, continuous film of anode ion impermeable substrate material having a uniform unit weight and perforated with a pattern of openings, each opening having a desired shape to provide for anode ion flow therethrough, wherein the substrate material is uniformly coated with an organic electron donor material.

13. The electrochemical cell of claim 12 wherein the substrate material is a flexible material.

14. The electrochemical cell of claim 12 wherein the substrate material is a synthetic material.

15. The electrochemical cell of claim 12 wherein the substrate material is made of a polyester material.

16. The electrochemical cell of claim 15 wherein the polyester material is polyethylene terephthalate film.

17. The electrochemical cell of claim 12 wherein the organic election donor material comprises poly-2-vinylpyridine.

18. The electrochemical cell of claim 12 wherein the anode is lithium.

19. The electrochemical cell of claim 12 wherein the covering is pressure-bonded to the anode surface.

20. The electrochemical cell of claim 12 wherein the anode surface is relatively flat and the covering is adhered to the surface.

21. The electrochemical cell of claim 12 wherein the anode surface is provided with formations to increase the surface area thereof and the covering is adhered to the surface.

22. The electrochemical cell of claim 12 further including a cathode comprising a charge transfer complex formed from iodine and poly-2-vinylpyridine.

23. The electrochemical cell of claim 12 wherein the covering is in the form of a unitary body.

24. The electrochemical cell of claim 12 wherein the pattern of openings provides the continuous film with about a 50% open area.

25. In a lithium-halogen electrochemical cell wherein a lithium anode has a surface in operative contact with a solid electrolyte, the improvement comprising:

a covering adhered to the lithium anode surface, the covering comprising a non-fabric, continuous film of anode ion impermeable substrate material having a uniform unit weight and perforated with a pattern of openings, each opening having a desired shape to provide for anode ion flow therethrough, wherein the substrate material is uniformly coated with an organic electron donor material.

26. The electrochemical cell of claim 25 wherein the substrate is a flexible material.

27. The electrochemical cell of claim 25 wherein the substrate material is a synthetic material.

28. The electrochemical cell of claim 25 wherein the substrate material is a polyester material film.

29. The electrochemical cell of claim 28 wherein the polyester material is polyethylene terephthalate.

30. The electrochemical cell of claim 25 wherein the organic election donor material comprises poly-2-vinylpyridine.

31. The electrochemical cell of claim 25 wherein the covering is pressure-bonded to the lithium anode surface.

32. The electrochemical cell of claim 25 wherein the lithium anode surface is relatively flat and the covering is adhered to the surface.

33. The electrochemical cell of claim 25 wherein the lithium anode surface is provided with formations to increase the surface area thereof and the covering is adhered to the surface.

34. The electrochemical cell of claim 25 further including a cathode comprising a charge transfer complex formed from iodine and poly-2-vinylpyridine.

35. The electrochemical cell of claim 25 wherein the covering is in the form of a unitary body.

36. The electrochemical cell of claim 25 wherein the pattern of openings provides the continuous film with about a 50% open area.

37. An anode for an alkali metal-halogen electrochemical cell comprising:

a) an anode body of alkali metal having a surface for operative contact with a solid electrolyte of the cell;

b) anode electrical conductor means operatively associated with the anode body; and

c) a covering on the anode surface, the covering comprising a non-fabric, continuous film of anode ion impermeable substrate material having a uniform unit weight and perforated with a pattern of openings, each opening having a desired shape to provide for ion flow therethrough, wherein the substrate material is uniformly coated with an organic electron donor material.

38. The anode of claim 37 wherein the body is lithium.

39. The anode of claim 37 wherein the substrate material is flexible.

40. The anode of claim 37 wherein the substrate material is a synthetic material.

41. The anode of claim 37 wherein the substrate material is a polyester material.

42. The anode of claim 41 wherein the polyester material is polyethylene terephthalate film.

43. The anode of claim 37 wherein the organic electron donor material comprises poly-2-vinylpyridine.

44. The anode of claim 37 wherein the covering is pressure-bonded to the anode surface.

45. The anode of claim 37 wherein the anode surface is relatively flat and the covering is adhered to the surface.

46. The anode of claim 37 wherein the anode surface is provided with formations to increase the surface area thereof and the covering is adhered to the surface.

47. The anode of claim 37 wherein the covering is in the form of a unitary body.

48. The anode of claim 37 wherein the pattern of openings provides the continuous film with about a 50% open area.

49. In an alkali metal-oxyhalide electrochemical cell wherein an alkali metal anode has a surface in operative contact with a liquid cathode/electrolyte, the improvement comprising:

a covering on the anode surface, the covering comprising a non-fabric, continuous film of anode ion impermeable substrate material having a uniform unit weight and perforated with a pattern of openings, each opening having a desired shape to provide for anode ion flow therethrough, wherein the substrate material is uniformly coated with an organic electron donor material.

50. The electrochemical cell of claim 49 wherein the anode is lithium.

51. The electrochemical cell of claim 49 wherein the substrate is flexible material.

52. The electrochemical cell of claim 49 wherein the substrate is a synthetic material.

53. The electrochemical cell of claim 49 wherein the substrate material is a polyester material.

54. The electrochemical cell of claim 53 wherein the polyester material is polyethylene terephthalate film.

55. The electrochemical cell of claim 49 wherein the organic electron donor material comprises poly-2-vinylpyridine.

56. The electrochemical cell of claim 49 wherein the covering is pressure-bonded to the anode surface.

57. The electrochemical cell of claim 49 wherein the covering is in the form of a unitary body.

58. The electrochemical cell of claim 49 wherein the pattern of openings provides the continuous film with about a 50% open area.

59. In an alkali metal-oxyhalide electrochemical cell wherein a lithium anode has a surface in operative contact with a liquid cathode/electrolyte, the improvement comprising:

a covering adhered to the lithium anode surface, the covering comprising a non-fabric, continuous film of anode ion impermeable substrate material having a uniform unit weight and perforated with a pattern of openings, each opening having a desired shape to provide for anode ion flow therethrough, wherein the substrate material is uniformly coated with an organic electron donor material.

60. The electrochemical cell of claim 59 wherein the substrate material is a synthetic material.

61. The electrochemical cell of claim 59 wherein the substrate material is a polyester material.

62. The electrochemical cell of claim 61 wherein the polyester material is polyethylene terephthalate film.

63. The electrochemical cell of claim 59 wherein the organic electron donor material comprises poly-2-vinylpyridine.

64. The electrochemical cell of claim 59 wherein the film is pressure-bonded to the lithium anode surface.

65. The electrochemical cell of claim 59 wherein the covering is in the form of a unitary body.

66. The electrochemical of claim 59 wherein the pattern of openings provides the continuous film with about a 50% open area.

67. The anode for alkali metal-oxyhalide electrochemical cell comprising:

a) an anode body of alkali metal having a surface for operative contact with a liquid electrolyte of the cell;

b) anode electrical conductor means operatively associated with the anode body; and

c) a covering on the anode surface, the covering comprising a non-fabric, continuous film of anode ion impermeable substrate material having a uniform unit weight and perforated with a pattern of openings, each opening having a desired shape to provide for anode ion flow therethrough, wherein the substrate material is uniformly coated with an organic electron donor material.

68. The anode of claim 67 wherein the anode body is lithium.

69. The anode of claim 67 wherein the substrate material is flexible.

70. The anode of claim 67 wherein the substrate is a synthetic material.

71. The anode of claim 67 wherein the substrate is a polyester material.

72. The anode of claim 71 wherein the polyester material is polyethylene terephthalate film.

73. An anode of claim 67 wherein the covering is pressure-bonded to the anode surface.

74. The anode of claim 67 wherein the covering is in the form of a unitary body.

75. The anode of claim 67 wherein the pattern of openings provides the continuous film with about a 50% open area.