Lithium anodes for electrochemical cells

• US 6,706,449 B2
• Filed: 12/18/2001
• Issued: 03/16/2004
• Est. Priority Date: 12/21/2000
• Status: Expired due to Term

• Current Assignee: Sion Power Corporation
• Original Assignee: Moltech Corporation
• Inventors: Skotheim, Terje A., Sheehan, Christopher J., Mikhaylik, Yuriy V.
• Primary Examiner(s): Kalafut, Stephen
• Assistant Examiner(s): DOVE, TRACY MAE
• Application Number:
  US10/025,651
• Publication Number:
  US 20020187398A1
• Time in Patent Office: 819 Days
• Field of Search: 429/208, 429/209, 429/212, 429/231.95, 429/232, 429/233, 429/245, 429/246
• US Class Current: 429/246
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 4/0402 Methods of deposition of the material
• CPC Class Codes: H01M 4/0407 by coating on an electrolyte layer
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/382 Lithium H01M4/405 takes precedence
• CPC Class Codes: H01M 4/405 Alloys based on lithium
• 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 4/5815 Sulfides
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• 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

Abstract

Provided are anodes for use in electrochemical cells, wherein the anode comprises an anode active layer comprising lithium and a polymer anode substrate comprising a polymer film layer and a protective crosslinked polymer layer, in which the protective crosslinked polymer layer is in contact with the anode active layer on the side opposite to the surface in contact with the polymer film layer. The present invention also pertains to methods for forming such anodes and electrochemical cells comprising such anodes.

Claims

1. An anode of an electrochemical cell, wherein said anode comprises:

(a) an anode active layer comprising lithium; and

(b) a polymer anode substrate wherein said polymer anode substrate comprises a polymer film layer and a protective crosslinked polymer layer;

wherein said protective crosslinked polymer layer is in contact with said anode active layer comprising lithium on the side opposite to the surface in contact with said polymer film layer.

2. The anode of claim 1, wherein said polymer film layer is a polyester film selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate, 1,4-cyclohexanedimethylene terephthalate, and polyethylene isophthalate.

3. The anode of claim 1, wherein said protective crosslinked polymer layer is formed from the polymerization of one or more monomers comprising a monomer selected from the group consisting of alkyl acrylates, glycol acrylates, polyglycol acrylates, and polyol polyacrylates.

4. The anode of claim 1, wherein said polymer film layer is from 2 to 25 microns in thickness.

5. The anode of claim 1, wherein said polymer film layer is from 2 to 10 microns in thickness.

6. The anode of claim 1, wherein said protective crosslinked polymer layer is from 0.01 to 4 microns in thickness.

7. The anode of claim 1, wherein said protective crosslinked polymer layer is from 0.1 to 2 microns in thickness.

8. The anode of claim 1, wherein said anode active layer comprising lithium is from 5 to 50 microns in thickness.

9. The anode of claim 1, wherein said anode comprises a metal current collector layer interposed between said protective crosslinked polymer layer and said anode active layer comprising lithium.

10. The anode of claim 9, wherein said metal current collector layer comprises a metal selected from the group consisting of copper and nickel.

11. The anode of claim 1, wherein said anode comprises a single ion conducting protective layer in contact with said anode active layer comprising lithium on the side opposite from said polymer anode substrate.

12. An electrochemical cell comprising:

(a) a cathode comprising a cathode active material;

(b) an anode; and

(c) a non-aqueous electrolyte interposed between said anode and said cathode, wherein said anode comprises;

(i) an anode active layer comprising lithium; and

(ii) a polymer anode substrate, wherein said polymer anode substrate comprises a polymer film layer and a protective crosslinked polymer layer wherein the protective crosslinked polymer layer is in contact with said anode active layer comprising lithium on the side opposite to the surface in contact with said polymer film layer.