ACTIVE METAL / AQUEOUS ELECTROCHEMICAL CELLS AND SYSTEMS

• US 20120009469A1
• Filed: 09/19/2011
• Published: 01/12/2012
• 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.
• Granted Patent: US 8,202,649 B2
• Time in Patent Office: Days
• US Class Current: 429/209
• 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 battery cell, comprising:

an active metal anode having a first surface and a second surface;

a cathode structure comprising an electronically conductive component, an ionically conductive component, and an electrochemically active component, wherein at least one cathode structure component comprises an aqueous constituent;

an ionically conductive protective membrane on the first surface of the anode, the membrane comprising,

one or more materials configured to provide a first surface chemically compatible with the active metal of the anode in contact with the anode, and a second surface substantially impervious to and chemically compatible with the cathode structure and in contact with the cathode structure.

2. An electrochemical cell structure, comprising:

an active metal anode having a first surface and a second surface;

a porous catalytic electronically conductive support;

an ionically conductive protective membrane on the first surface of the anode, the membrane comprising,

one or more materials configured to provide a first surface chemically compatible with the active metal of the anode, and a second surface substantially impervious to and chemically compatible with the catalytic electronically conductive support, and aqueous environments.

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

assembling an active metal anode and a cathode structure comprising an electronically conductive component;

wherein a protective membrane is disposed between the active metal anode and the cathode structure, the membrane being ionically conductive and chemically compatible with an active metal on a first side, and substantially impervious, ionically conductive and chemically compatible the cathode structure on the other side;

and wherein an active metal material is applied to the first side of the protective membrane to form the active metal anode.