Lithium ion battery and capacitor hybrid system in a single pouch

• US 10,297,885 B2
• Filed: 02/04/2016
• Issued: 05/21/2019
• Est. Priority Date: 03/25/2015
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Gayden, Xiaohong Q., Yu, Zhiqiang, Liu, Haijing
• Primary Examiner(s): Lyles-Irving, Carmen V
• Application Number:
  US15/015,227
• Publication Number:
  US 20160285137A1
• Time in Patent Office: 1,202 Days
• Field of Search: None
• 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 11/08 Structural combinations, e.g. assembly or connection, of hybrid or EDL capacitors with other electric components, at least one hybrid or EDL capacitor being the main component
• 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 11/28 arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
• CPC Class Codes: H01G 11/34 characterised by carbonisation or activation of carbon
• CPC Class Codes: H01G 11/46 Metal oxides
• CPC Class Codes: H01G 11/58 Liquid electrolytes
• CPC Class Codes: H01G 11/62 characterised by the solute, e.g. salts, anions or cations therein
• CPC Class Codes: H01G 11/66 Current collectors
• CPC Class Codes: H01G 11/72 specially adapted for integration in multiple or stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/78 Cases; Housings; Encapsulations; Mountings
• CPC Class Codes: H01G 11/86 specially adapted for electrodes carbonisation or activation of carbon for the manufacture of electrodes H01G11/34
• CPC Class Codes: H01M 10/0459 Cells or batteries with folded separator between plate-like electrodes
• 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 10/0568 characterised by the solutes
• CPC Class Codes: H01M 10/0583 of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with "Z"-shaped electrodes or separators
• CPC Class Codes: H01M 10/4264 with capacitors
• CPC Class Codes: H01M 12/02 Details of electrodes H01M4/00; of non-active parts H01M50/00
• CPC Class Codes: H01M 16/00 Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 4/0404 : by coating on electrode collectors
• 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 4/661 : Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 50/10 : Primary casings; Jackets or wrappings
• CPC Class Codes: H01M 50/105 : Pouches or flexible bags
• 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: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries

Abstract

Lithium-ion battery cells and a lithium-ion utilizing capacitor cells are placed spaced-apart in a common container and infiltrated with a common lithium-ion transporting, liquid electrolyte. The lithium-ion-utilizing capacitor and lithium-ion cell battery are combined such that their respective electrodes may be electrically connected, either in series or parallel connection for energy storage and management in an automotive vehicle or other electrical power supply application.

Claims

1. An enclosed hybrid combination of a (i) a unitary assembly consisting of one or more lithium-ion battery electrochemical cells, each battery cell having a layered structure and (ii) a unitary assembly consisting of one or more electrochemical capacitor cells, each capacitor cell having a layered structure, the unitary assembly of lithium-ion battery cells and the unitary assembly of capacitor cells being physically separated from each other while enclosed in a single common sealed container, the enclosed lithium-ion battery assembly and the enclosed capacitor assembly both being in contact with a single, common, lithium ion conducting, liquid electrolyte solution for the electrochemical performance of their respective capacitor and battery functions;

the layered battery cells and layered capacitor cells of the hybrid combination being further characterized as follows;

each layered lithium-ion battery cell comprises an anode current collector layer with two opposing faces and an anode electrical connector tab, a porous layer of particulate battery cell anode material deposited on each face of the anode current collector, a cathode current collector layer with two opposing faces and a cathode electrical connector tab, a porous layer of particulate battery cell cathode material deposited on each face of the cathode current collector, and a porous battery cell separator layer physically separating facing porous layers of battery cell anode material and cathode material, each layered lithium-ion battery cell being exclusive of capacitor anode material or capacitor cathode material;

each layered capacitor cell comprises an anode current collector layer with two opposing faces and an anode electrical connector tab, a porous layer of particulate capacitor anode electrode material deposited on each face of the anode current collector, a cathode current collector layer with two opposing faces and a cathode electrical connector tab, a porous layer of particulate capacitor cell cathode material deposited on each face of the cathode electrode current collector, and a porous capacitor cell separator layer physically separating all facing porous layers of capacitor cell anode material and cathode material, the capacitor cell separator layer being distinct from the battery cell separator layer, each layered capacitor cell being exclusive of battery anode material or battery cathode material; and

the common lithium ion electrolyte solution comprising a lithium salt dissolved in a non-aqueous solvent for battery cell function and capacitor cell function.

2. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as stated in claim 1 in which porous layer electrodes and separators of the lithium-ion battery and the porous layer electrodes and separators of the capacitor are formed with the same rectangular shapes and rectangular side dimensions.

3. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as stated in claim 1 in which the layered structure of the lithium battery and the layered structure of the capacitor are separated from each other in their common sealed container by a distance in the range of 0.01 mm to 10 mm.

4. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as stated in claim 1 in which the outer layer of the layered structure of the lithium battery is a porous separator layer and the outer layer of the layered structure of the capacitor is a porous separator layer and the porous separator layers serve to separate the lithium-ion battery and the capacitor from each other in their common sealed container.

5. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as stated in claim 1 in which the outer layer of the layered structure of the lithium battery is a porous separator layer and the outer layer of the layered structure of the capacitor is a porous separator layer and the outer porous separator layers are separated from each other in their common sealed container by a distance in the range of 0.01 mm to 10 mm.

6. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 1 in which the battery and capacitor are placed in a polymer-coated aluminum foil pouch.

7. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 1 in which the battery and capacitor are placed in a polymer-coated metal foil pouch having an polymeric interior structure that physically separates the battery and capacitor while permitting ionic-conductivity by the common electrolyte contacting each of them.

8. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 1 in which the cathode current collector foil for each cell of the battery and capacitor is an aluminum foil and the anode current collector foil for each cell of the battery and capacitor is a copper foil.

9. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 1 in which each battery cell cathode connector tab is connected as a battery cathode terminal which extends outside the common sealed container, each battery cell anode connector tab is connected as a battery anode terminal which extends outside the common sealed container, each capacitor cell cathode connector tab is connected as a capacitor cathode terminal which extends outside the common sealed container, and each capacitor cell anode connector tab is connected as a capacitor anode terminal which extends outside the common sealed container.

10. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 1 in which the capacitor cathode material and the capacitor anode material each comprises activated carbon.

11. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 1 in which the battery cell anode material is Li₄Ti₅O₁₂ spinel.

12. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 1 in which the battery cell cathode active material is LiMn₂O₄ spinel.

13. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 1 in which the common electrolyte comprises a lithium salt selected from the group consisting of lithium hexafluorophosphate (LiPF₆), lithium tetrafluoroborate (LiBF₄), lithium perchlorate (LiClO₄), lithium hexafluoroarsenate (LiAsF₆), and lithium trifluoroethanesulfonimide.

14. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 13 in which the lithium salt is dissolved in one or more non-aqueous solvents selected from the group consisting of ethylene carbonate, dimethyl carbonate, methylethyl carbonate, and propylene carbonate.

15. An enclosed hybrid combination of a (i) a unitary assembly consisting of one or more lithium-ion battery electrochemical cells, each battery cell having a layered structure with opposing faces of each layer, rectangular sides and an end face and (ii) a unitary assembly consisting of one or more electrochemical capacitor cells, each capacitor cell having a layered structure with opposing faces of each layer, rectangular sides of the same dimensions as the sides of the battery cell, and an end face, the unitary assembly of lithium-ion battery cells and the unitary assembly of capacitor cells being enclosed in a single common sealed container with the end face of a battery cell spaced up to 10 mm from the end face of a capacitor cell, the enclosed lithium-ion battery assembly and the enclosed capacitor assembly both being in contact with a single, common, lithium ion conducting, liquid electrolyte solution for the electrochemical performance of their respective capacitor and battery functions;

the layered battery cells and layered capacitor cells of the hybrid combination being further characterized as follows;

each layered lithium-ion battery cell comprises an anode current collector layer with two opposing faces and an anode electrical connector tab, a porous layer of particulate battery cell anode material deposited on each face of the anode current collector, a cathode current collector layer with two opposing faces and a cathode electrical connector tab, a porous layer of particulate battery cell cathode material deposited on each face of the cathode current collector, and a porous battery cell separator layer physically separating facing porous layers of battery cell anode material and cathode material, each layered lithium-ion battery cell being exclusive of capacitor anode material or capacitor cathode material;

each layered capacitor cell comprises an anode current collector layer with two opposing faces and an anode electrical connector tab, a porous layer of particulate capacitor anode electrode material deposited on each face of the anode current collector, a cathode current collector layer with two opposing faces and a cathode electrical connector tab, a porous layer of particulate capacitor cell cathode material deposited on each face of the cathode electrode current collector, and a porous capacitor cell separator layer physically separating facing porous layers of capacitor cell anode material and cathode material, the capacitor cell separator layer being distinct from the battery cell separator layer, each layered capacitor cell being exclusive of battery anode material or battery cathode material; and

the common lithium ion electrolyte solution comprising a lithium salt dissolved in a non-aqueous solvent for battery cell function and capacitor cell function.

16. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 15 in which the battery and capacitor are placed in a polymer-coated metal foil pouch having an polymeric interior structure that physically separates the battery and capacitor while permitting ionic-conductivity by the common electrolyte contacting each of them.

17. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 15 in which the battery and capacitor are placed in a polymer-coated metal foil pouch with facing layers of porous separator material.

18. A hybrid combination of a (i) lithium-ion battery and (ii) a capacitor as recited in claim 15 in which each battery cell cathode connector tab is connected as a battery cathode terminal which extends outside the common sealed container, each battery cell anode connector tab is connected as a battery anode terminal which extends outside the common sealed container, each capacitor cell cathode connector tab is connected as a capacitor cathode terminal which extends outside the common sealed container, and each capacitor cell anode connector tab is connected as a capacitor anode terminal which extends outside the common sealed container.