Battery structures, self-organizing structures and related methods

• US 7,988,746 B2
• Filed: 09/20/2010
• Issued: 08/02/2011
• Est. Priority Date: 10/20/2000
• Status: Expired due to Fees

• Current Assignee: A123 Systems Incorporated, Massachusetts Institute of Technology
• Original Assignee: A123 Systems Incorporated, Massachusetts Institute of Technology
• Inventors: Moorehead, William D., Viola, Michael S., Loxley, Andrew L., Riley, Gilbert N. Jr., Chiang, Yet-Ming, Holman, Richard K., Gozdz, Antoni S.
• Primary Examiner(s): Maples; John S
• Application Number:
  US12/886,035
• Publication Number:
  US 20110005065A1
• Time in Patent Office: 316 Days
• Field of Search: None
• US Class Current: 29/623.1
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G02F 1/1524 Transition metal compounds
• CPC Class Codes: G02F 2001/1555 Counter electrode
• CPC Class Codes: H01G 11/02 using combined reduction-oxidation reactions, e.g. redox arrangement or solion
• CPC Class Codes: H01G 11/06 with one of the electrodes allowing ions to be reversibly doped thereinto, e.g. lithium ion capacitors [LIC]
• CPC Class Codes: H01G 11/24 characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosity; characterised by the structural features of powders or particles used therefor
• CPC Class Codes: H01G 11/26 characterised by their structure, e.g. multi-layered, porosity or surface features
• CPC Class Codes: H01G 11/28 arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
• CPC Class Codes: H01G 11/56 Solid electrolytes, e.g. gels; Additives therein
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 10/0472 Vertically superposed cells with vertically disposed plates
• 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 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2004/025 with shapes other than plane or cylindrical
• CPC Class Codes: H01M 4/808 Foamed, spongy materials
• 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: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49002 : Electrical device making
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 29/49115 : including coating or impregnating
• CPC Class Codes: Y10T 29/49224 : with coating

Abstract

An energy storage device includes a first electrode comprising a first material and a second electrode comprising a second material, at least a portion of the first and second materials forming an interpenetrating network when dispersed in an electrolyte, the electrolyte, the first material and the second material are selected so that the first and second materials exert a repelling force on each other when combined. An electrochemical device, includes a first electrode in electrical communication with a first current collector; a second electrode in electrical communication with a second current collector; and an ionically conductive medium in ionic contact with said first and second electrodes, wherein at least a portion of the first and second electrodes form an interpenetrating network and wherein at least one of the first and second electrodes comprises an electrode structure providing two or more pathways to its current collector.

Claims

1. A method for producing a bipolar device comprising:

providing a medium, particles of a first type comprising a first electroactive material and particles of a second type comprising a second electroactive material, wherein the medium is electronically-insulating and ionically-conductive;

combining the particles of the first type and second type in the medium, wherein the particles of the first type and second type exert a repelling force on one another;

segregating at least a portion of the particles of the first type into a first spatial region that is essentially free of particles of the second type to form a first network of electronically-connected particles of the first type; and

segregating at least a portion of the particles of the second type into a second spatial region that is essentially free of particles of the first type to form a second network of second electronically-connected particles.

2. The method of claim 1, wherein the first and the second network are interpenetrating.

3. The method of claim 1, wherein the particles of the first type are self-attractive in the medium.

4. The method of claim 1, wherein the particles of the second type are self-attractive in the medium.

5. The method of claim 1, wherein the particles of the first type and the second type repel each other in the medium.

6. The method of claim 1, wherein a first Hamaker constant characterizing the interaction of the particles of the first type with themselves is positive.

7. The method of claim 1, wherein a second Hamaker constant characterizing the interaction of the particles of the second type with themselves is positive.

8. The method of claim 1, wherein particles of the first type has a refractive index n₁, the medium has a refractive index n₂, and particles of the second type has a refractive index n₃;

and wherein n₁<

n₂<

n₃.

9. The method of claim 8, wherein particles of the first type comprise a first coating material and wherein the first coating material has a refractive index of n₁.

10. The method of claim 8, wherein particles of the second type comprise a second coating material and wherein the second coating material has a refractive index of n₃.

11. The method of claim 1, wherein the repelling force comprises van der Waals forces.

12. The method of claim 1, wherein the repelling force comprises electrostatic forces.

13. The method of claim 1, wherein the repelling force comprises molecular steric forces.

14. The method of claim 1, wherein the steps of segregating at least a portion of the particles of the first type and segregating at least a portion of the particles of the second type are performed essentially simultaneously.

15. The method of claim 1, wherein segregating at least a portion of the particles of the first type comprises allowing at least a portion of the particles of the first type to float to the first spatial region.

16. The method of claim 14, wherein segregating at least a portion of the particles of the first type comprises allowing at least a portion of the particles of the first type to float to the first spatial region.

17. The method of claim 1, wherein segregating at least a portion of the particles of the first type comprises allowing at least a portion of the particles of the first type to sink to the first spatial region.

18. The method of claim 14, wherein segregating at least a portion of the particles of the first type comprises allowing at least a portion of the particles of the first type to sink to the first spatial region.

19. The method of claim 1, further comprising the step of immobilizing the first and second networks.

20. The method of claim 1, further comprising providing a first current collector in electronic communication with the first network and a second current collector in electronic communication with the second network.

21. The method of claim 20, wherein the first current collector comprises electronically-connected particles of the first type.

22. The method of claim 20, wherein the second current collector comprises electronically-connected particles of the second type.

23. The method of claim 20, wherein the first current collector is electronically-connected to the first network and the second current collector is electronically-connected to the second network.

24. The method of claim 20, further comprising the step of immobilizing the first and second networks.

25. The method of claim 20, wherein the particles of the first type and the second current collector repel each other in the medium.

26. The method of claim 20, wherein the particles of the second type and the first current collector repel each other in the medium.

27. The method of claim 25, wherein the second current collector is coated with a third coating material and wherein the particles of the first type and the third coating material repel each other in the medium.

28. The method of claim 26, wherein the first current collector is coated with a fourth coating material and wherein the particles of the second type and the fourth coating material repel each other in the medium.

29. The method of claim 17, further comprising the step of immobilizing the first and second networks.

30. The method of claim 19, wherein the step of immobilizing comprises allowing the medium to solidify.

31. The method of claim 29, wherein the step of immobilizing comprises allowing the medium to solidify.

32. The method of claim 30, wherein the step of immobilizing comprises allowing the medium to solidify.

33. The method of claim 1, wherein the particles of the first type comprise at least one of LiCoO₂, LiCoO₂ doped with Mg, LiNiO₂, LiMn₂O₄, LiMnO₂, LiMnO₂ doped with Al, Li(Fe,Mn)PO₄, LiFePO₄, LiFePO₄ doped with one or more of Mg, Al, Ti, Nb, Ta, Zr, or W, Li₂Fe₂(SO₄)₃, V₂O₅, V₆O₁₁, C, amorphous carbon, graphite, mesocarbon microbeads, Li, LiAl, Li₉Al₄, Li₃Al, Zn, LiZn, Ag, LiAg, Li₁₀Ag₃, B, Li₅B₄, Li₇B₆, Ge, Si, Li₁₂Si₇, Li₂₁Si₈, Li₁₃Si₄, Li₂₁Si₅, Sn, Li₅Sn₂, Li₁₃Sn₅, Li₇Sn₂, Li₂₂Sn₅, Sb, Li₂Sb, Li₃Sb, Bi, LiBi, Li₃Bi, SnO₂, SnO, MnO, Mn₂O₃, MnO₂, Mn₃O₄, CoO, NiO, FeO, LiFe₂O₄, TiO₂, LiTi₂O₄, glass with a Sn—

B—

P—

O compound and mesocarbon microbeads coated with at least one of poly(o-methoxyaniline), poly(3-octylthiophene), and poly(vinylidene fluoride).

34. The method of claim 1, wherein the particles of the second type comprise at least one of LiCoO₂, LiCoO₂ doped with Mg, LiNiO₂, LiMn₂O₄, LiMnO₂, LiMnO₂ doped with Al, Li(Fe,Mn)PO₄, LiFePO₄, LiFePO₄ doped with one or more of Mg, Al, Ti, Nb, Ta, Zr, or W, Li₂Fe₂(SO₄)₃, V₂O₅, V₆O₁₁, C, amorphous carbon, graphite, mesocarbon microbeads, Li, LiAl, Li₉Al₄, Li₃Al;

Zn, LiZn, Ag, LiAg, Li₁₀Ag₃, B, Li₅B₄, Li₇B₆, Ge, Si, Li₁₂Si₇, Li₂₁Si₈, Li₁₃Si₄, Li₂₁Si₅, Sn, Li₅Sn₂, Li₁₃Sn₅, Li₇Sn₂, Li₂₂Sn₅, Sb, Li₂Sb, Li₃Sb, Bi, LiBi, Li₃Bi, SnO₂, SnO, MnO, Mn₂O₃, MnO₂, Mn₃O₄, CoO, NiO, FeO, LiFe₂O₄, TiO₂, LiTi₂O₄, glass with a Sn—

B—

P—

O compound and mesocarbon microbeads coated with at least one of poly(o-methoxyaniline), poly(3-octylthiophene), and poly(vinylidene fluoride).

35. The method of claim 1, wherein the medium comprises at least one of poly(ethylene oxide), poly(styrene), poly(acrylonitrile), poly(vinylidene fluoride), diiodomethane, 1,3-diiodopropane, N,N-dimethylformamide, dimethylpropylene urea, ethylene carbonate, diethylene carbonate, dimethyl carbonate, propylene carbonate, a block copolymer lithium electrolyte doped with a lithium salt, glass with at least one of LiI, LiF, LiCl, Li₂O—

B₂O₃—

Bi₂O₃, Li₂O—

B₂O₃—

P₂O₅ and Li₂O—

B₂O₃—

PbO and a sol or gel of the oxides or hydroxides of Ti, Zr, Pb, or Bi.

36. The method of claim 1, wherein the medium comprises a solid polymeric material or a precursor thereto.

37. The method of claim 1, wherein the bipolar device is a battery.