Electric vehicle propulsion system and method utilizing solid-state rechargeable electrochemical cells

• US 9,929,440 B2
• Filed: 08/08/2016
• Issued: 03/27/2018
• Est. Priority Date: 04/01/2011
• Status: Active Grant

• Current Assignee: Sakti3, Inc
• Original Assignee: Sakti3, Inc
• Inventors: Sastry, Ann Marie, Albano, Fabio, Wang, Chia-Wei, Kruse, Robert, Lebrun, Jeffrey
• Primary Examiner(s): RHEE, JANE J
• Application Number:
  US15/231,300
• Publication Number:
  US 20160344065A1
• Time in Patent Office: 596 Days
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• 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 10/054 Accumulators with insertion or intercalation of metals other than lithium, e.g. with magnesium or aluminium
• 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 10/0587 of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
• CPC Class Codes: H01M 10/63 Control systems charging or discharging in response to temperature H01M10/44 , H01M10/443; measurement of temperature H01M10/48 , H01M10/486
• CPC Class Codes: H01M 10/658 by thermal insulation or shielding
• 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 2300/0068 inorganic
• CPC Class Codes: H01M 2300/0071 Oxides
• CPC Class Codes: H01M 2300/0082 Organic polymers
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/136 Electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
• CPC Class Codes: H01M 4/40 Alloys based on alkali metals
• CPC Class Codes: H01M 4/405 Alloys based on lithium
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• 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

A vehicle propulsion system comprising a plurality of solid state rechargeable battery cells configured to power a drivetrain. In accordance with once aspect of the invention, a transportation system that is powered at least in part by electricity stored in the form of rechargeable electrochemical cells. According to an embodiment of the present invention, these cells are combined in series and in parallel to form a pack that is regulated by charge and discharge control circuits that are programmed with algorithms to monitor state of charge, battery lifetime, and battery health.

Claims

1. A battery consisting of a single substrate layer supporting a plurality of electrochemical cells, the single substrate layer comprising a flexible thermoplastic polymer and having a surface region and a thickness of less than 10 microns, the plurality of electrochemical cells comprising:

a first electrochemical cell comprising a first current collector layer, a first positive electrode layer, a first solid state layer of electrolyte, and a first negative electrode layer; and

a second electrochemical cell comprising a second current collector layer, a second positive electrode layer, a second solid state layer of electrolyte, and a second negative electrode layer,

wherein the first electrochemical cell and the second electrochemical cell are arranged in a stacked configuration overlying the surface region of the single substrate layer.

2. The battery of claim 1, wherein the substrate layer comprises at least one of a polyethylene terephthalate (PET), a biaxxially oriented polypropylenefilm (BOPP), a polyethylene naphtahalate (PEN), polyester, a polypropylene and an acrylact.

3. The battery of claim 1, wherein the polymer is not capable of being annealed.

4. The battery of claim 1, wherein the substrate layer has a thickness which is less than 5 microns.

5. The battery of claim 1, wherein the surface region of the substrate layer has an area which is at least 0.01 m².

6. The battery of claim 1, wherein the first solid state layer of electrolyte has a thickness which is less than 5 microns.

7. The battery of claim 1, wherein the second solid state layer of electrolyte has a thickness which is less than 5 microns.

8. The battery of claim 1, wherein the first positive electrode layer has a thickness which is less than 50 microns.

9. The battery of claim 8, wherein the first positive electrode layer has a thickness which is less than 10 microns.

10. The battery of claim 1, wherein the second positive electrode layer has a thickness which is less than 50 microns.

11. The battery of claim 10, wherein the first negative electrode layer has a thickness which is less than 50 microns.

12. The battery of claim 1, wherein the second negative electrode layer has a thickness which is less than 50 microns.

13. The battery of claim 1, wherein the first positive electrode layer comprises a transition metal oxide or a transition metal phosphate.

14. The battery of claim 1, wherein the second positive electrode layer comprises a transition metal oxide or a transition metal phosphate.