CN103904298A - 通过共挤出印刷而制得的先进高功率和高能量的电池电极 - Google Patents

通过共挤出印刷而制得的先进高功率和高能量的电池电极 Download PDF

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CN103904298A
CN103904298A CN201310683501.XA CN201310683501A CN103904298A CN 103904298 A CN103904298 A CN 103904298A CN 201310683501 A CN201310683501 A CN 201310683501A CN 103904298 A CN103904298 A CN 103904298A
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C-J·贝
E·J·施雷德
C·L·科布
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Abstract

本发明提供了一种电池，其具有阳极、与所述阳极相邻的分离器、和与所述阳极相对的与所述分离器相邻的阴极，所述阴极包括交指型材料条，所述材料中的一种形成孔穴通道。

Description

通过共挤出印刷而制得的先进高功率和高能量的电池电极
背景技术
电池电极设计通常必须在能量密度与功率密度之间获得权衡。能量密度通常被认为是每单位质量在给定系统或空间区域中所储存的能量的量。功率密度为材料传导电流的能力的量度。通常，具有高能量密度(即高储存容量)的装置不快速放电，这意味着它们同时不具有高功率。
在供电应用中强烈需要增加的体积能量密度的锂离子(Li离子)电池。在多处存在所述需要，如用于可远程驾驶的电动车辆(EV)、混合EV和无线电动工具。具体对于EV，可使用Li离子驱动的EV的距离与体积能量密度直接相关。目前的Li离子电池对于功率要求满足或超过美国先进电池联盟(USABC)的目标，但对于体积能量密度仅满足他们推荐目标的60％。为了增加Li离子电池的体积能量密度，重要的是降低Li离子电池中的非活性组分的体积。
图1显示了典型的Li离子电池10，其中活性材料由用于阴极18的氧化钴锂(LiCoO2)和用于阳极部分的石墨20组成。非活性部件由电解质、粘结剂、碳、分离器14和正负集电器12和16组成。图2显示了在放电过程中Li离子如何通过图1中的液体电解质的部分20从阳极传输至阴极电极。使用导电致密电极，可发生液体电解质24中的离子的局部消耗。该现象限制了临界电流密度，在电流进一步增加时这可导致放电容量减小。具有更短的Li离子扩散长度22的大约100微米的更薄的电极可用于常规Li离子电池中以减小该效应。
对于目前的EV应用，通过堆叠许多常规薄电极的层而制得大的电池。这导致在这些电池中大比例的非活性组分。降低昂贵的分离器和沉重的集电器的量将大大降低费用和存在的非活性材料的量。图4显示，使用更厚的电极(如36)的Li离子传输路径38提供了一种直接实际的解决方法，所述解决方法以增加活性材料与非活性材料的比例的方式增加Li离子电池的体积能量密度。然而，图4显示了使用更厚的电极(如36)的问题。由于更长的扩散路径(如38)，电解质消耗由于在扩散路径中在复杂微结构中的较差的Li离子电导率而增加。目前的工业制造过程限制了电极构造可获得的改进。
附图说明
图1和2显示了常规锂离子电池的现有技术构造。
图3和4显示了使用厚电极增加锂离子电池的体积能量密度的现有技术构造。
图5显示了具有包括直线孔穴通道的厚的高能量密度电极的电池的一个实施例。
图6显示了具有提供快速锂离子路径的直线孔穴通道的电极的一个实施例的更详细的视图。
图7和8显示了在充电和放电过程中具有直线孔穴通道的电极的扩散路径。
图9显示了制造电池电极的方法的一个实施例的流程图。
具体实施方式
图5显示了具有不同类型的电极的电池的一个实施例。电池50具有集电器52和56、阴极58、与所述阴极相邻的分离器54和与所述阴极相对的与分离器相邻的阳极60。在该实施例中，阴极58由交指型材料条组成。
这些类型的电池电极的例子描述于美国专利7,765,949、7,780,812、7,922,471和美国专利公布20120156364和20120153211中。美国专利7,765,949公开了一种用于在基材上挤出和分配材料的装置，所述装置具有用于接收材料的至少两个通道和用于将材料挤出至基材上的出口端口。美国专利7,780,812公开了具有平面化边缘表面的另一个这种装置。美国专利7,922,471公开了用于挤出材料的另一个这种装置，所述材料具有在沉积于基材上之后不沉淀的平衡形状。美国专利公布20120156364和20120153211公开了一种共挤出头，所述共挤出头将两种或更多种材料的流合并成在基材上的交指型结构，其中存在所述材料的多个条。
图5中的电池50具有阴极，所述阴极具有交指型的材料条。这些条可由公开于如上专利和公布中的共挤出装置(其也可称为印刷头)形成。该结构可由其他类型的装置形成。另外，可使用本文公开的实施例形成其他类型的结构。电池电极由所公开的材料和实施例的用途的仅一个例子组成。
常规挤出方法无法通过将多个粘性的填充粒子的糊剂进料至印刷头而产生导电触点和间隔的交指型条，所述印刷头允许分开的流体流动以交替聚集。由于在如上微共挤出印刷头中的层状流动，因此两种材料通常不混合。图6显示了图5的交指型结构的部分70的分解图。
交指型材料条的材料中的一者形成作为电极结构内的微结构的孔穴通道。用于产生该结构的条和材料的形成将在以下更详细地描述。孔穴通道(如64)起到了用以促进Li离子移动的槽(sink)或源的关键作用。当Li离子通过所述孔穴通道从另一材料62转移时，这些通道产生更短且更少弯曲的路径。这允许使用更厚的电极，这在其他情况中是不可能的。所得阴极具有高功率和体积能量密度。
图7和8显示了用于槽和源位点的扩散路径。图7显示了在充电过程中朝向孔穴通道64通过基体62的扩散路径80。图8显示了在放电过程中从孔穴通道朝向基体62的扩散路径82。朝向基体和来自基体的路径更短，且孔穴通道允许极快的扩散路径，所述基体为阴极中的另一材料的条。
到目前为止，讨论涉及结构，但现在转向制造如这些的结构的方法。图9显示了用以制造交指型电极的一个实施例的总体流程图。通常，方法涉及在90处混合第一活性材料与溶剂，以制得第一电极活性材料。溶剂允许材料变薄以使其更容易地流动通过共挤出装置。所述第一活性材料和第二活性材料可通常为相同的材料，但具有不同的浓度。为了该讨论的目的，第一材料为具有更高浓度的材料。
第二材料在92处以相同的方式制得。然后在94处使用如上讨论的或另一类型的共挤出装置或印刷头将两种活性材料在一起挤出。当材料在基材上的适当位置时，去除溶剂，留下活性材料在基材上的各自位置处。然后通过在98处提供分离器和在100处提供阳极，从而完成电池。
所述方法的目标之一是提供具有间隙间隔的分散的粒度，以用于在具有较低浓度的活性材料的材料条中形成孔穴通道。该方法可以以数种不同的方式进行。本讨论将涉及室温方法和高温方法。对于室温实施例，活性阴极材料可由如下组成：氧化钴锂(LCO)、氧化锰钴镍锂(NCM)、或两者的混合物。其他材料可包括氧化铝钴镍锂(NCA)、氧化锰锂(LMO)、磷酸铁锂(LFeP)。尽管本文的活性材料中的许多为锂，但这些技术可应用于钠离子电池和镁离子电池。阳极材料可为石墨和钛酸锂(LTA)。在该特定实施例中，材料与诸如聚偏氟乙烯(PVDF)的粘结剂混合，且溶剂由n-甲基-2-吡咯烷酮(NMP)组成。也可添加聚氧乙烯油烯基醚(也称为Brij98)形式的分散剂。可添加炭黑以增加电导率。
这些材料形成为两种不同的浆料，其中一种浆料相比于另一种浆料具有更高浓度的活性材料。共挤出装置将浆料沉积于基材上，然后去除溶剂。在室温实施例中，溶剂被干燥出浆料，留下材料在它们各自的位置处。
在高温实施例中，活性材料由LCO组成。用于该实施例中的粘结剂为乙基纤维素树脂，如由陶氏化学公司(Dow Chemical company)制造的EthocelTM。在该特定实施例中所用的溶剂由癸二酸二乙酯和丁基卡必醇的混合物组成。分散剂可由亚麻酸组成。混合物可沉积，然后在高温下烧结以去除溶剂并留下材料。
在任一情况中，所得材料在较低浓度下具有广泛的粒度分布。这允许形成作为电极中的微结构的孔穴通道。所得电极具有高度受控的微结构，所述微结构提供快的锂离子扩散路径，解决电解质消耗问题，从而制得高能高功率电极。相比于常规电池电极，这些电极显示出更好的电化学性能。
相反，由于常规电池电极通常由集电器箔上的糊剂制得，且所述糊剂使用流延成型铺展，因此常规电池电极仅具有简单的单片微结构。

Claims (6)

1.一种电池，其包括：
阳极；
与所述阳极相邻的分离器；和
与所述阳极相对的与所述分离器相邻的阴极，所述阴极包括交指型材料条，所述材料中的一种形成孔穴通道。
2.根据权利要求1所述的电池，其还包括与所述分离器相对的与所述阳极和所述阴极相邻的集电器。
3.根据权利要求1所述的电池，其中所述交指型材料条包括第一材料，所述第一材料具有比第二材料更低的锂浓度。
4.根据权利要求1所述的电池，其中所述阴极包括活性材料，所述活性材料为氧化钴锂或氧化锰钴镍锂。
5.根据权利要求1所述的电池，其中所述阴极包括如下中的一者的活性材料：氧化铝钴镍锂(NCA)、氧化锰锂(LMO)或磷酸铁锂(LFeP)。
6.根据权利要求1所述的电池，其中所述阳极包括交指型材料条，所述材料中的一种形成孔穴通道。
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