Lithium anodes for electrochemical cells

• US 7,247,408 B2
• Filed: 05/23/2001
• Issued: 07/24/2007
• Est. Priority Date: 11/23/1999
• Status: Expired due to Term

• Current Assignee: Sion Power Corporation
• Original Assignee: Sion Power Corporation
• Inventors: Skotheim, Terje A., Sheehan, Christopher J., Mikhaylik, Yuriy V., Affinito, John
• Primary Examiner(s): Barr; Michael
• Assistant Examiner(s): WILLS, MONIQUE M
• Application Number:
  US09/864,890
• Publication Number:
  US 20020012846A1
• Time in Patent Office: 2,253 Days
• Field of Search: 429/231.95, 429/209, 429/218.1, 429/236, 429/245, 296/235, 427/123, 427/126.3
• US Class Current: 429/231.95
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/056 characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
• CPC Class Codes: H01M 10/0585 of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• CPC Class Codes: H01M 10/4235 Safety or regulating additives or arrangements in electrodes, separators or electrolyte H01M10/4242 takes precedence
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0421 involving vapour deposition
• CPC Class Codes: H01M 4/0426 Sputtering
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/136 Electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
• CPC Class Codes: H01M 4/1395 of electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/38 of elements or alloys
• CPC Class Codes: H01M 4/382 Lithium H01M4/405 takes precedence
• CPC Class Codes: H01M 4/387 Tin or alloys based on tin
• CPC Class Codes: H01M 4/581 Chalcogenides or intercalation compounds thereof
• CPC Class Codes: H01M 4/5815 : Sulfides
• CPC Class Codes: H01M 4/625 : Carbon or graphite
• CPC Class Codes: H01M 4/628 : Inhibitors, e.g. gassing inhibitors, corrosion inhibitors
• CPC Class Codes: H01M 50/46 : Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: H01M 6/14 : Cells with non-aqueous electrolyte
• CPC Class Codes: H01M 6/18 : with solid electrolyte
• CPC Class Codes: H01M 6/40 : Printed batteries , e.g. thin film batteries
• 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

Abstract

Provided is an anode for use in electrochemical cells, wherein the anode active layer has a first layer comprising lithium metal and a multi-layer structure comprising single ion conducting layers and polymer layers in contact with the first layer comprising lithium metal or in contact with an intermediate protective layer, such as a temporary protective metal layer, on the surface of the lithium-containing first layer. Another aspect of the invention provides an anode active layer formed by the in-situ deposition of lithium vapor and a reactive gas. The anodes of the current invention are particularly useful in electrochemical cells comprising sulfur-containing cathode active materials, such as elemental sulfur.

Claims

1. A method of making an anode of an electrochemical cell in a vacuum chamber wherein the method comprises:

(a) providing a moving substrate;

(b) moving the substrate consecutively past a lithium vapor deposition source, wherein the source is characterized by a nozzle through which lithium vapor is emitted;

(c) providing reactive gaseous material adjacent to the lithium deposition nozzle; and

(d) condensing the lithium vapor of (b) on the substrate in presence of gaseous material to co-deposit a lithium anode active layer to form the anode.

2. The method of claim 1, wherein the lithium vapor is condensed on the substrate by contacting the substrate with a cooled surface as the substrate passes through the vapor.

3. The method of claim 1, wherein the thickness of the co-deposited lithium layer of the anode is from 2 μ

m to 100 μ

m.

4. The method of claim 1, wherein the thickness of the co-deposited lithium layer of the anode is from 5 μ

m to 50 μ

m.

5. The method of claim 1, wherein the substrate is selected from the group consisting of metal foils, polymer films, and metallized polymer films.

6. The method of claim 5, wherein the polymer film is selected from the group consisting of films of polyethylene terephthalate, polyethylene naphthalate, 1,4-cyclohexanedimethylene terephthalate, polyethylene isophthalate, and polybutylene terephthalate.

7. The method of claim 1, wherein the gaseous material is selected from one or more of the group consisting of carbon dioxide, acetylene, nitrogen, ethylene, sulfur dioxide, hydrocarbons, alkyl phosphate esters, alkyl sulfite esters, and alkyl sulfate esters.

8. The method of claim 1, wherein the gaseous material is carbon dioxide.