Battery including aluminum components

• US 7,279,250 B2
• Filed: 11/24/2003
• Issued: 10/09/2007
• Est. Priority Date: 11/24/2003
• Status: Active Grant

• Current Assignee: Duracell U.S. Operations, Inc. (Berkshire Hathaway Incorporated)
• Original Assignee: Gillette Company (The Procter & Gamble Company)
• Inventors: Berkowitz, Fred J., Issaev, Nikolai N., Pozin, Michael
• Primary Examiner(s): Crepeau; Jonathan
• Assistant Examiner(s): CHUO, TONY SHENG HSIANG
• Application Number:
  US10/719,025
• Publication Number:
  US 20050112467A1
• Time in Patent Office: 1,415 Days
• Field of Search: 429/245
• US Class Current: 429/245
• CPC Class Codes: H01M 2004/028 Positive electrodes
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 4/5815 Sulfides
• CPC Class Codes: H01M 4/5825 Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/53135 Storage cell or battery

Abstract

A primary lithium battery can include a current collector that includes aluminum, a cap that includes aluminum, or both. The aluminum battery components can have high mechanical strength and low electrical resistance.

Claims

1. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including an aluminum alloy and a cathode active material including a manganese dioxide, a CF_x iron disulfide, or a vanadate in contact with the current collector; and

a separator between the anode and the cathode,

wherein the aluminum alloy is a 6000 series aluminum alloy and includes 0.04-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.1-7% by weight of magnesium, 0.15% or less by weight of manganese, and 0.4-0.8% by weight of silicon.

2. The battery of claim 1, wherein the lithium-containing anode active material is lithium or a lithium alloy.

3. The battery of claim 1, wherein the-aluminum alloy includes 0.15-0.4% by weight of copper, 0.7% or less by weight of iron, “

0.8-1.2% by weight of magnesium”

;

0.1% or less by weight of titanium, and 0.25% or less by weight of zinc.

4. The battery of claim 1, further comprising a nonaqueous electrolyte in contact with the anode, the cathode, and the separator.

5. The battery of claim 4, wherein the nonaqueous electrolyte includes an organic solvent.

6. The battery of claim 4, wherein the nonaqueous electrolyte includes a perchlorate salt.

7. The battery of claim 1, wherein the current collector is an expanded metal grid.

8. The battery of claim 7, wherein the current collector has a yield strength of at least 2.0 lb/in.

9. The battery of claim 7, wherein the current collector has a yield strength of at least 5 lb/in.

10. The battery of claim 7, wherein the current collector has a tensile strength of at least 5 lb/in.

11. The battery of claim 7, wherein the current collector has a tensile strength of at least 7 lb/in.

12. The battery of claim 7, wherein the current collector has a yield strength of at least 2.0 lb/in and a tensile strength of at least 5 lb/in.

13. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including an aluminum alloy and a cathode active material selected from the group consisting of metal oxides and metal halides in contact with the current collector, wherein the current collector has a resistivity of less than 100 mΩ

/cm; and

a separator between the anode and the cathode,

wherein the aluminum alloy is a 6000 series aluminum alloy and includes 0.04-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.1-7% by weight of magnesium, 0.15% or less by weight of manganese, and 0.4-0.8% by weight of silicon.

33. The method of claim 13, wherein the current collector is a metal grid and a portion of the metal grid consists of the aluminum alloy.

14. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including an aluminum alloy and a cathode active material selected from the group consisting of metal oxides and metal halides in contact with the current collector, wherein the current collector has a resistivity of less than 10 Ω

/cm; and

a separator between the anode and the cathode,

wherein the aluminum alloy is a 6000 series aluminum alloy and includes 0.04-0.4% by weight of chromium, 0.0 1-6.8% by weight of copper, 0.1-7% by weight of magnesium, 0.15% or less by weight of manganese, and 0.4-0.8% by weight of silicon.

34. The method of claim 14, wherein the current collector is a metal grid and a portion of the metal grid consists of the aluminum alloy.

15. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including an aluminum alloy and a cathode active material including a manganese dioxide in contact with the current collector;

a separator between the anode and the cathode; and

a non-aqueous electrolyte including an organic solvent and a perchlorate salt in contact with the anode, the cathode and the separator,

wherein the aluminum alloy is a 6000 series aluminum alloy and includes 0.04-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.1-7% by weight of magnesium, 0.15% or less by weight of manganese, and 0.4-0.8% by weight of silicon.

16. The battery of claim 15, wherein the current collector is an expanded metal grid.

17. The battery of claim 16, wherein the current collector has a yield strength of at least 2.0 lb/in.

18. The battery of claim 16, wherein the current collector has a yield strength of at least 5 lb/in.

19. The battery of claim 16, wherein the current collector has a tensile strength of at least 5 lb/in.

20. The battery of claim 16, wherein the current collector has a tensile strength of at least 7 lb/in.

21. A primary lithium battery comprising:

an anode including a lithium-containing anode active material; and

a cathode including a current collector including a 6061 aluminum alloy and a cathode active material selected from the group consisting of metal oxides and metal halides in contact with the current collector.

22. The battery of claim 21, wherein the cathode active material is a solid.

23. The battery of claim 21, wherein the cathode active material is a liquid.

24. The battery of claim 21, wherein the cathode active material includes SO₂ or SOCl₂.

25. The battery of claim 21, wherein the current collector includes a pulled grid.

26. The battery of claim 21, wherein the current collector includes a leveled grid.

27. A method of making a primary lithium battery comprising assembling a solid cathode including a manganese dioxide, a CF_x, iron disulfide, or a vanadate and a current collector including an aluminum alloy, an anode including lithium, and a separator in a housing,

wherein the aluminum alloy is a 6000 series aluminum alloy and includes 0.04-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.1-7% by weight of magnesium, 0.15% or less by weight of manganese, and 0.4-0.8% by weight of silicon.

28. The method of claim 27, wherein the aluminum alloy includes 0.15-0.4% by weight of copper, 0.7% or less by weight of iron, 0.8-1.2% by weight of magnesium, 0.15% or less by weight of titanium, and 0.25% or less by weight of zinc.

29. The method of claim 27, wherein the current collector is an expanded metal grid.

30. The method of claim 27, further comprising placing a nonaqueous electrolyte in the housing.

31. The method of claim 30, wherein the nonaqueous electrolyte includes an organic solvent.

32. The method of claim 30, wherein the nonaqueous electrolyte includes a perchlorate salt.

35. A primary lithium battery comprising:

an anode including a lithium-containing anode active material;

a solid cathode including a current collector including an aluminum alloy and a cathode active material selected from the group consisting of metal oxides and metal halides in contact with the current collector; and

a separator between the anode and the cathode,

wherein the aluminum alloy is a 6000 series aluminum alloy and includes 0.04-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.1-7% by weight of magnesium, 0.15% or less by weight of manganese, and 0.4-0.8% by weight of silicon.

36. A method of making a primary lithium battery comprising assembling a solid cathode including a cathode active material including a manganese dioxide, a CF_x, iron disulfide, or a vanadate and a current collector including an aluminum alloy, an anode including lithium, and a separator in a housing,

wherein the aluminum alloy is a 6000 series aluminum alloy and includes 0.04-0.4% by weight of chromium, 0.01-6.8% by weight of copper, 0.1-7% by weight of magnesium, 0.15% or less by weight of manganese, and 0.4-0.8% by weight of silicon.