Protected lithium electrodes having tape cast ceramic and glass-ceramic membranes

• US 9,136,568 B2
• Filed: 05/04/2012
• Issued: 09/15/2015
• Est. Priority Date: 10/14/2003
• Status: Active Grant

• Current Assignee: PolyPlus Battery Company
• Original Assignee: PolyPlus Battery Company
• Inventors: Visco, Steven J., Nimon, Yevgeniy S.
• Primary Examiner(s): Kelly, Cynthia H
• Assistant Examiner(s): WILLS, MONIQUE M
• Application Number:
  US13/464,835
• Publication Number:
  US 20120219842A1
• Time in Patent Office: 1,229 Days
• Field of Search: 429/231.95, 429/128, 429/131, 429/142, 429/144, 429/218.1, 429/231.9
• US Class Current: 1/1
• 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 10/058 Construction or manufacture
• CPC Class Codes: H01M 10/24 Alkaline accumulators
• CPC Class Codes: H01M 10/36 Accumulators not provided for in groups H01M10/05-H01M10/34
• CPC Class Codes: H01M 10/38 Construction or manufacture
• CPC Class Codes: H01M 12/06 with one metallic and one gaseous electrode
• CPC Class Codes: H01M 12/08 composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
• CPC Class Codes: H01M 16/00 Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 16/003 of fuel cells with other electrochemical devices, e.g. capacitors, electrolysers
• CPC Class Codes: H01M 2300/0071 Oxides
• CPC Class Codes: H01M 2300/0094 in the form of layered products, e.g. coatings
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/382 Lithium H01M4/405 takes precedence
• CPC Class Codes: H01M 4/405 Alloys based on lithium
• CPC Class Codes: H01M 4/628 Inhibitors, e.g. gassing inhibitors, corrosion inhibitors
• CPC Class Codes: H01M 50/414 Synthetic resins, e.g. thermoplastics or thermosetting resins
• CPC Class Codes: H01M 50/431 Inorganic material
• CPC Class Codes: H01M 50/434 Ceramics
• CPC Class Codes: H01M 50/437 Glass
• CPC Class Codes: H01M 50/451 : comprising layers of only organic material and layers containing inorganic material
• CPC Class Codes: H01M 6/04 : Cells with aqueous electrolyte
• CPC Class Codes: H01M 6/34 : Immersion cells, e.g. sea-water cells
• CPC Class Codes: H01M 8/1016 : characterised by the electrolyte material H01M8/12 takes precedence
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• 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
• CPC Class Codes: Y10T 29/4911 : including sealing
• CPC Class Codes: Y10T 29/49115 : including coating or impregnating

Abstract

Alkali (or other active) metal battery and other electrochemical cells incorporating active metal anodes together with aqueous cathode/electrolyte systems. The battery cells have a highly ionically conductive protective membrane adjacent to the alkali metal anode that effectively isolates (de-couples) the alkali metal electrode from solvent, electrolyte processing and/or cathode environments, and at the same time allows ion transport in and out of these environments. Isolation of the anode from other components of a battery cell or other electrochemical cell in this way allows the use of virtually any solvent, electrolyte and/or cathode material in conjunction with the anode. Also, optimization of electrolytes or cathode-side solvent systems may be done without impacting anode stability or performance. In particular, Li/water, Li/air and Li/metal hydride cells, components, configurations and fabrication techniques are provided.

Claims

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

tape-casting an inherently ionically conductive substantially impervious alkali metal ion ionically conducting membrane selected from the group consisting of a glass-ceramic and a glass, the membrane having a first surface and a second surface; and

assembling the tape-cast inherently ionically conductive protective membrane with an alkali metal anode adjacent to the first surface

wherein the membrane effectively isolates the alkali metal anode from environments deleterious to the alkali metal while allowing transport of ions of the alkali metal from the first surface to the second surface, the membrane having conductivity for ions of the anode alkali metal of at least 10<sup>−

6</sup> S/cm.

2. The method of claim 1, wherein the tape-cast ionically conductive membrane is a glass-ceramic.

3. The method of claim 1, wherein the tape-cast ionically conductive membrane is a glass.

4. The method of claim 1, wherein following tape-casting, the ionically conductive membrane is fired to full density.

5. The method of claim 1, wherein the electrochemical cell structure further comprises a support structure.

6. The method of claim 5, wherein the tape-cast ionically conductive membrane is disposed on the support structure.

7. The method of claim 6, wherein the support structure is porous.

8. The method of claim 7, wherein the support structure is selected from the group consisting of a polymeric support, a metal support, a glass support, a glass-ceramic support, and a ceramic support.

9. The method of claim 1, wherein the alkali metal is lithium.