Protected active metal electrode and battery cell structures with non-aqueous interlayer architecture

• US 9,123,941 B2
• Filed: 07/31/2014
• Issued: 09/01/2015
• Est. Priority Date: 02/06/2004
• Status: Active Grant

• Current Assignee: PolyPlus Battery Company
• Original Assignee: PolyPlus Battery Company
• Inventors: Visco, Steven J., Katz, Bruce D., Nimon, Yevgeniy S., De Jonghe, Lutgard C.
• Primary Examiner(s): DOVE, TRACY MAE
• Application Number:
  US14/449,040
• Publication Number:
  US 20150024251A1
• Time in Patent Office: 397 Days
• Field of Search: 429/126, 429/328, 429/339, 429/345
• US Class Current: 1/1
• 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 11/52 Separators
• CPC Class Codes: H01G 11/58 Liquid electrolytes
• 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 10/0562 Solid materials
• CPC Class Codes: H01M 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 2300/0002 Aqueous electrolytes
• CPC Class Codes: H01M 2300/0085 Immobilising or gelification of electrolyte
• CPC Class Codes: H01M 4/13 Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 50/451 comprising layers of only organic material and layers containing inorganic material
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: H01M 50/497 Ionic conductivity
• 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 29/49108 Electric battery cell making

Abstract

Active metal and active metal intercalation electrode structures and battery cells having ionically conductive protective architecture including an active metal (e.g., lithium) conductive impervious layer separated from the electrode (anode) by a porous separator impregnated with a non-aqueous electrolyte (anolyte). This protective architecture prevents the active metal from deleterious reaction with the environment on the other (cathode) side of the impervious layer, which may include aqueous or non-aqueous liquid electrolytes (catholytes) and/or a variety of electrochemically active materials, including liquid, solid and gaseous oxidizers. Safety additives and designs that facilitate manufacture are also provided.

Claims

1. A method of making an electrochemical cell structure, comprising:

providing an active metal anode component;

providing an ionically conductive protective architecture component, the protective architecture component comprising,

an active metal ion conducting separator layer comprising a semi-permeable polymer membrane comprising a non-aqueous anolyte, the separator layer being chemically compatible with the active metal, and

a substantially impervious ionically conductive layer chemically compatible with the separator layer; and

assembling the components such that the separator layer of the protective architecture component is in contact with a first surface of the anode component.

2. The method of claim 1, wherein the active metal anode component is an active lithium anode, and further wherein the protective architecture component is conductive to lithium ions.

3. The method of claim 2, wherein the active lithium anode is selected from the group consisting of lithium metal, lithium alloy and lithium intercalating material.

4. The method of claim 3, wherein the active lithium anode is lithium metal.

5. The method of claim 3, wherein the active lithium anode comprises a lithium intercalating material.

6. The method of claim 5, wherein the lithium intercalating material comprises intercalatable carbon.

7. The method of claim 3, wherein the active lithium anode comprises a lithium silicon alloy.

8. The method of claim 2, wherein the substantially impervious layer is a glass.

9. The method of claim 2, wherein the substantially impervious layer is a ceramic.

10. The method of claim 2, wherein the substantially impervious layer is a glass-ceramic.

11. The method of claim 2, wherein the substantially impervious layer has a thickness in the range of 10 to 1000 microns.

12. The method of claim 2, wherein the substantially impervious layer has a lithium ion conductivity of at least 10⁻

5 S/cm

13. The method of claim 2, wherein the anolyte is a liquid phase lithium ion conductor.

14. The method of claim 2, wherein the anolyte is a gel phase lithium ion conductor.

15. The method of claim 1, wherein the active metal is lithium, the substantially impervious layer has a thickness in the range of 10-1000 microns.

16. The method of claim 15, wherein the substantially impervious layer has a thickness in the range of 10-1000 microns.

17. The method of claim 16, wherein the substantially impervious layer has a lithium ion conductivity of at least 10⁻

5 S/cm.

18. The method of claim 17, wherein the anolyte comprises a liquid phase lithium ion conductor.

19. The method of claim 18, wherein the substantially impervious layer is a ceramic lithium ion conductor.

20. The method of claim 18, wherein the substantially impervious layer is a glass-ceramic.