Bipolar articles and related methods

• US 8,481,208 B2
• Filed: 06/16/2010
• Issued: 07/09/2013
• Est. Priority Date: 07/26/2002
• Status: Active Grant

• Current Assignee: A123 Systems Incorporated
• Original Assignee: A123 Systems Incorporated
• Inventors: Riley, Gilbert N. Jr., Chiang, Yet-Ming, Gozdz, Antoni S., Viola, Michael S., Fulop, Ricardo
• Primary Examiner(s): APICELLA, KARIE O
• Application Number:
  US12/816,644
• Publication Number:
  US 20100248028A1
• Time in Patent Office: 1,119 Days
• Field of Search: 429210-212, 427/115
• US Class Current: 429/210
• CPC Class Codes: H01M 10/18 with bipolar electrodes
• CPC Class Codes: H01M 4/38 of elements or alloys
• 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 4/505 of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
• CPC Class Codes: H01M 4/525 of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 4/64 Carriers or collectors
• CPC Class Codes: H01M 4/66 Selection of materials
• CPC Class Codes: H01M 4/668 Composites of electroconductive material and synthetic resins
• CPC Class Codes: H01M 6/48 with bipolar electrodes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/53135 Storage cell or battery
• CPC Class Codes: Y10T 29/532 Conductor

Abstract

The invention provides bipolar articles (e.g., batteries and capacitors) with new architectures and methods of making and using the same. Articles are provided with interpenetrating anode and cathode structures that allow for improved power density, and arbitrary form factors that allow for formation in substantially any desired shape. The articles are useful for embedding or integral formation in various electronic devices to provide more efficient use of space in the devices. The articles optionally include self-organizing bipolar structures.

Claims

1. A bipolar article, the article comprising:

(a) a housing comprising an inside surface and an outside surface;

wherein the inside surface has an arbitrary form factor which is independent of the form factor of the outside surface and is not cylindrical or prismatic;

(b) a bipolar structure comprising a cathode current collector, an anode current collector, an anode, a cathode, and an electrolyte in contact with and separating the anode and cathode;

wherein the anode and cathode are interpenetrating;

the cathode current collector is in electronic communication with the cathode; and

the anode current collector is in electronic communication with the anode;

wherein the bipolar structure as a whole has an arbitrary form that is not cylindrical or prismatic; and

at least one of the cathode, the anode, and their respective current collectors has an arbitrary form that is not cylindrical or prismatic and is conformal to the inside surface of the housing.

2. The bipolar article of claim 1, wherein the housing is an outer casing of the bipolar article.

3. The bipolar article of claim 1, wherein the housing is a housing of a battery powered device.

4. The bipolar article of claim 1, wherein the anode, electrolyte, and cathode are sequentially deposited.

5. The bipolar article of claim 1, wherein the bipolar article is a battery.

6. The bipolar article of claim 1, wherein the anode includes one or more materials selected from the group consisting of carbon, 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, and Li₃Bi, SnO₂, SnO, MnO, Mn₂O₃, MnO₂, Mn₃O₄, CoO, NiO, FeO, LiFe₂O₄, TiO₂, LiTi₂O₄, and glass.

7. The bipolar article of claim 1, wherein the cathode includes one or more materials selected from the group consisting of LiCoO₂, LiCoO₂ doped with Mg, LiNiO₂, LiMn₂O₄, LiMnO₂, LiMnO₂ doped with Al, doped and undoped LiFePO₄, LiMnPO₄, LixV₆O₁₃, Li₂Fe₂(SO₄)₃, V₂O₅, V₆O₁₁, and SnO₂.

8. The bipolar article of claim 1, having a power density greater than about 300 W/kg.

9. A device comprising the bipolar article of claim 1.

10. The device of claim 9, wherein the arbitrary form factor of the bipolar article is conformal with at least one surface of the device.

11. The device of claim 9, wherein the device has a cavity, and wherein the arbitrary form factor of the bipolar article is space-filling within the cavity.

12. The device of claim 9, wherein the device is a cellular telephone, laptop computer, personal digital assistant, or toy.