Classifications

• • H—ELECTRICITY
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  • H01M4/04—Processes of manufacture in general
  • H01M4/0402—Methods of deposition of the material
  • H01M4/0404—Methods of deposition of the material by coating on electrode collectors
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
  • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
  • C23C16/26—Deposition of carbon only
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  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
  • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
  • C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
  • C23C16/45523—Pulsed gas flow or change of composition over time
  • C23C16/45525—Atomic layer deposition [ALD]
  • C23C16/45553—Atomic layer deposition [ALD] characterized by the use of precursors specially adapted for ALD
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  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
  • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
  • C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
  • C23C16/45523—Pulsed gas flow or change of composition over time
  • C23C16/45525—Atomic layer deposition [ALD]
  • C23C16/45555—Atomic layer deposition [ALD] applied in non-semiconductor technology
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
  • C25D13/00—Electrophoretic coating characterised by the process
  • C25D13/12—Electrophoretic coating characterised by the process characterised by the article coated
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  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/052—Li-accumulators
  • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
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  • H01M4/0438—Processes of manufacture in general by electrochemical processing
  • H01M4/045—Electrochemical coating; Electrochemical impregnation
  • H01M4/0457—Electrochemical coating; Electrochemical impregnation from dispersions or suspensions; Electrophoresis
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  • H01M4/0471—Processes of manufacture in general involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
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  • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
  • H01M4/485—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy
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  • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
  • H01M4/581—Chalcogenides or intercalation compounds thereof
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  • H01M4/582—Halogenides
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  • H01M4/5825—Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
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  • H01M4/1315—Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx containing halogen atoms, e.g. LiCoOxFy
• • H—ELECTRICITY
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  • H01M4/13915—Processes of manufacture of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx containing halogen atoms, e.g. LiCoOxFy
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
  • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

• the invention relates to the field of electrochemistry, and more particularly to thin-film electrochemical systems. It relates more precisely to the electrodes which can be used in electrochemical systems such as lithium ion microbatteries.
• the invention applies to negative electrodes and positive electrodes. It relates to porous electrodes which can be impregnated with a solid electrolyte without a liquid phase or with a liquid electrolyte.
• the invention also relates to a process for preparing such a porous electrode which uses nanoparticles of an electrode material, and the electrodes thus obtained.
• the invention also relates to a method of manufacturing a lithium ion microbattery comprising at least one of these electrodes, and the microbatteries thus obtained.
• Lithium ion batteries have the best energy density among the various electrochemical storage technologies available on the market. There are different architectures and chemical compositions of electrodes to make these batteries. The manufacturing processes for lithium ion batteries are presented in numerous articles and patents; an inventory is given in the book “Advances in Lithium-Ion Batteries” (ed. W. van Schalkwijk and B. Scrosati), published in 2002 (Kluever internationale / Plénum Publishers).
• microbatteries i.e. rechargeable batteries of very small size, capable of being integrated on electronic cards; these electronic circuits can be used in many fields, for example in cards to secure transactions, in electronic labels, in implantable medical devices, in various micromechanical systems.
• the electrodes of lithium ion batteries can be manufactured using coating techniques, in particular by roller coating (in English “roll coating”), doctor blade coating (in English “ doctor blade ”), tape casting, coating through a slot-shaped die.
• roller coating in English "roll coating”
• doctor blade coating in English “ doctor blade ”
• tape casting coating through a slot-shaped die.
• an ink consisting of particles of active materials in the form of powder is deposited on the surface of a substrate; the particles constituting this powder have an average particle size which is typically between 5 ⁇ m and 15 ⁇ m in diameter.
• the power and energy of the battery can be modulated by adapting the thickness and porosity of the layers, and the size of the active particles that constitute them.
• the inks (or pastes) deposited to form the electrodes contain particles of active materials, but also (organic) binders, carbon powder to ensure electrical contact between the particles, and solvents which are evaporated during the step of drying the electrodes.
• a calendering step is carried out on the electrodes. After this compression step, the active particles of the electrodes occupy about 60% of the volume of the deposit, which means that there is generally about 40% of porosities between the particles.
• dense layers devoid of porosity; thus the volume energy density of the electrode is maximum.
• dense layers can be produced using vacuum deposition techniques, for example by physical vapor deposition (abbreviated PVD, "Physical Vapor Deposition”).
• PVD physical vapor deposition
• conductive filler electronic conductive charges
• an electrode having 30% porosity containing conductive charges and impregnated with an electrolyte conductive of lithium ions, would have a higher volume energy density of about 35% relative to the same electrode at 50% porosity consisting of particles monodisperse in size.
• the thickness of these electrodes can be greatly increased compared to what is possible with the techniques of vacuum deposition, which lead to compact but more resistive layers. This increase in the thickness of the electrodes increases the energy density of the battery cells thus obtained.
• Binder-free mesoporous electrode layers for lithium ion batteries can be deposited by electrophoresis; this is known from WO 2019/215407 (1-TEN). They can be impregnated with a liquid electrolyte, but their electrical resistivity remains quite high.
• the liquid electrolytes used for the impregnation of porous electrodes consist of aprotic solvents in which lithium salts have been dissolved. They are very flammable and can give rise to violent combustions of the battery cells, especially when the active cathode materials are stressed in voltage ranges outside their stability voltage range, or when hot spots appear locally in the battery. cell.
• ionic liquids which are extremely stable in temperature.
• ionic liquids do not wet the surfaces of organic materials, and the presence of PVDF and other organic binders in the electrodes of conventional lithium ion batteries prevents wetting of the electrodes by this type of electrolyte; the performance of the electrodes is affected. Ceramic separators have been developed to solve this problem at the level of the electrolytic junction between electrodes, but the fact remains that the presence of organic binders in the electrodes continues to pose problems for the use of electrolytes based. ionic liquids.
• a third axis one can seek to homogenize the distribution and distribution of conductive charges (usually carbon black) in the electrode, in order to avoid locally having more electrically resistive zones which could lead to the formation of a hot spot during battery power operation.
• conductive charges usually carbon black
• their manufacturing cost depends in part on the nature of the solvents and the inks used. In addition to the intrinsic cost of the active materials, the cost of manufacturing the electrodes comes essentially from the complexity of the inks used (binders, solvents, carbon black).
• the main solvent used for making lithium ion battery electrodes is N-methyl-2-pyrrolidone (abbreviated NMP).
• NMP is an excellent solvent for dissolving PVDF which acts as a binder in the formulation of inks.
• the drying of the NMP contained in the electrodes is of real economic importance.
• the high boiling point of NMP coupled with its very low vapor pressure makes it difficult to dry in an industrial environment. Solvent vapors must be collected and reprocessed.
• the drying temperature of the NMP must not be too high, which tends to increase the drying time and its cost once again; this is described in the publication “Technical and economy analysis of solvent-based lithium-ion electrode drying with water and NMP” by DL Wood & al., published in the journal Drying Technology, vol. 36, n ° 2 (2016).
• inks Other less expensive solvents can be used to make inks, including water and ethanol.
• their surface tension is greater than that of NMP, and they therefore wet the surface of metallic current collectors less well.
• particles tend to agglomerate in water, especially carbon black nanoparticles. These agglomerations lead to a heterogeneous distribution of the components entering into the composition of the electrode (binders, carbon black, etc.).
• traces of water can remain adsorbed on the surface of particles of active materials, even after drying.
• the problem that the present invention seeks to solve is to provide a novel electrode for a lithium ion microbattery endowed with a very high energy density coupled with a very high power density, which exhibits excellent cycle life as well. that increased security.
• electrolytes based on organic solvents are replaced by mixtures of organic solvents and ionic liquids or by ionic liquids, which are extremely stable in temperature.
• ionic liquids do not wet on the surfaces of organic materials and the presence of PVDF and other organic binders in the electrodes of conventional batteries prevents wetting of the electrodes by this type of electrolyte, and the performance of the electrodes is affected. affected. Ceramic separators have been developed to solve this problem at the level of the electrolytic junction between electrodes, but the fact remains that the presence of organic binders in the electrodes continues to pose problems for the use of electrolytes based. ionic liquids.
• conductive additives in English "conductive fillers”; only carbon black is used in practice
• an electrode for a lithium ion microbattery which is completely ceramic, mesoporous devoid of organic binders, and whose porosity is between 50% and 25%, and whose channel and pore size is homogeneous in order to ensure perfect dynamic balancing of the cell.
• This entirely solid mesoporous structure, without organic components, is obtained by the deposition, on a substrate, of agglomerates and / or aggregates of nanoparticles of active materials.
• the sizes of the primary particles constituting these agglomerates and / or aggregates are of the order of nanometers or tens of nanometers, and the agglomerates and / or aggregates contain at least four primary particles.
• Said substrate may be, in a first embodiment, a substrate capable of acting as an electric current collector, or be, in a second embodiment, an intermediate, temporary substrate which will be explained in more detail below.
• agglomerates of a few tens or even hundreds of nanometers in diameter rather than primary, non-agglomerated particles each with a size of the order of one nanometer or ten nanometers makes it possible to increase the deposit thicknesses.
• the agglomerates should be less than 300 nm in size.
• the sintering of Agglomerates larger than 500 nm would not make it possible to obtain a continuous mesoporous film.
• two different porosity sizes are observed in the deposit, namely a porosity between agglomerates and a porosity inside the agglomerates.
• h max 0.41 [(GM0 rcp R 3 ) / 2 Y ] where h max denotes the critical thickness, G the shear modulus of the nanoparticles, M the number of coordination, 0 rc the volume fraction of nanoparticles, R the radius of the particles and g the interfacial tension between the solvent and the air.
• agglomerates mesoporous, made up of primary nanoparticles at least ten times smaller than the size of the agglomerate, considerably increases the cracking limit thickness of the layers.
• a lower surface tension solvent such as isopropyl alcohol (abbreviated IPA)
• IPA isopropyl alcohol
• binders and dispersants can be removed by heat treatment in air, such as by debinding, during a sintering treatment or during a heat treatment carried out prior to the sintering treatment.
• These primary nanoparticles have identical sizes regardless of the size of the agglomerate.
• the size distribution of the agglomerates will make it possible to improve the compactness of the deposits and to multiply the points of contact between nanoparticles, but will not modify the consolidation temperature.
• the agglomerates must remain small in order to be able to form during the heat treatment of the layer a continuous mesoporous film. If the agglomerates are too large, this hinders their sintering and the formation of two distinct porosities in the layer is observed: a porosity between agglomerates and a porosity inside the agglomerates.
• a porous layer preferably mesoporous, or a plate, without carbon black or organic binders, is obtained, in which all the nanoparticles are welded together (by the necking phenomenon, known elsewhere) to form a continuous mesoporous network characterized by unimodal porosity.
• the porous, preferably mesoporous, layer thus obtained is entirely solid and ceramic. There is no longer any risk of loss of electrical contact between the particles of active materials during cycling, which is likely to improve the cycling performance of the battery.
• the porous, preferably mesoporous, layer adheres perfectly to the metal substrate on which it has been deposited or transferred (in the case of an initial deposit on an intermediate substrate).
• the heat treatments carried out at high temperature to sinter the nanoparticles together allow the electrode to dry perfectly and remove all traces of water or solvents or other organic additives (stabilizers, binders) adsorbed on the surface of the particles. of active material.
• the high temperature heat treatment (sintering) can be preceded by a lower temperature heat treatment (debinding) to dry the placed or deposited electrode and to remove traces of water or solvents or other organic additives ( stabilizers, binders) adsorbed on the surface of the particles of active material; this debinding can be carried out in an oxidizing atmosphere.
• the porosity of the final electrode can be adjusted within a range of 50% to 25% porosity.
• the power density of the electrodes thus obtained remains extremely high due to the mesoporosity.
• the balancing cell dynamics remain perfect, which helps to maximize the power densities and battery cell lifetimes.
• the electrode according to the invention has a high specific surface, which reduces the ionic resistance of the electrode. However, for this electrode to deliver maximum power, it must still have very good conductivity. electronic to avoid ohmic losses in the battery. This improvement in the electronic conductivity of the cell will be all the more critical the greater the thickness of the electrode. Furthermore, this electronic conductivity must be perfectly homogeneous throughout the electrode in order to avoid the local formation of hot spots.
• a coating of an electronically conductive material is deposited on and inside the pores of the porous layer.
• This electronically conductive material can be deposited by the atomic layer deposition technique (abbreviated ALD, Atomic Layer Deposition) or from a liquid precursor.
• Said electronically conductive material may be carbon.
• the mesoporous layer can be immersed in a rich solution of a carbon precursor (eg, a solution of a carbohydrate, such as sucrose). Then the electrode is dried and subjected to heat treatment under nitrogen at a temperature sufficient to pyrolize the carbon precursor. This forms a very thin coating of carbon over the entire internal surface of the electrode, which is perfectly distributed. This coating gives the electrode good electronic conduction, regardless of its thickness. It should be noted that this treatment is possible after sintering because the electrode is entirely solid, without organic residues, and withstands the thermal cycles imposed by the various thermal treatments.
• a carbon precursor eg, a solution of a carbohydrate, such as sucrose
• a first object of the invention is a method of manufacturing a porous electrode, in particular for electrochemical devices, said electrode comprising a porous layer deposited on a substrate, said layer being free of binder, having a porosity of between 20% and 60%. % by volume, preferably between 25% and 50%, and pores with an average diameter of less than 50 nm, said manufacturing process being characterized in that:
• a layer is deposited on at least one face of said substrate by a process selected from the group formed by: electrophoresis, a printing process, in particular the inkjet printing process or flexographic printing , a coating process and preferably doctor blade, ie by scraping, roller, curtain, dipping or through a slot-shaped die from said colloidal suspension or paste supplied in step (a),
• step (c) said layer obtained in step (b) is dried, where appropriate before or after having separated said layer from its intermediate substrate, then, optionally, said dried layer is heat treated, preferably under an oxidizing atmosphere, and it is consolidated, by pressing and / or heating, to obtain a porous layer, preferably mesoporous,
• the electrode obtained can be coated with an ionic conductive layer in order to improve the life of the batteries and their performance.
• the ionic conductive layer can be Lii, 3Alo, 3Tii, 7 (P04) 3, nafion, U3BO3, PEO, or even a mixture of PEO and a phase carrying lithium ions, such as salts. lithium.
• step (b) the deposition can be done on one or on both sides of the substrate.
• said layer is separated in step (c) from said intermediate substrate, to form, after consolidation, a porous plate. This separation step can be carried out before or after the drying of the layer obtained in step b).
• an electrically conductive sheet is supplied, covered on at least one face, respectively on its two faces, with a thin layer of conductive glue or a thin layer of nanoparticles of at least one active electrode material P, then at least one porous plate is glued on one side, preferably on each side, of the electrically conductive sheet, so as to obtain a porous, preferably mesoporous, layer on a substrate capable of acting as a current collector.
• said colloidal suspension or paste supplied in step (a) comprises organic additives, such as ligands, stabilizers, binders or residual organic solvents
• said dried layer is heat treated, preferably under an oxidizing atmosphere.
• This heat treatment, allowing debinding, can be carried out at the same time as the consolidation (sintering) when it is carried out under an oxidizing atmosphere or before the step of consolidating the dried layer in step c).
• said substrate is a substrate capable of acting as an electric current collector.
• a metal substrate is chosen, which can in particular be made of tungsten, molybdenum, chromium, titanium, tantalum, stainless steel, or an alloy of two or more of these materials. Such metal substrates are quite expensive and can greatly increase the cost of the battery. This metal substrate can also be coated with a conductive or semiconductor oxide before depositing the layer of material P.
• the thickness of the layer after step (c) is advantageously between approximately 1 ⁇ m and approximately 300 ⁇ m.
• the thickness of the layer after step (c) is limited in order to avoid any cracking problem.
• said substrate is an intermediate, temporary substrate, such as a flexible substrate, which may be a polymer film.
• the deposition step is advantageously carried out on one face of said intermediate substrate in order to facilitate the subsequent separation of the layer from its substrate.
• the layer can be separated from its substrate after drying, preferably before heating it, but at the latest at the end of step (c).
• the thickness of the layer after step (c) is advantageously less than or equal to 5 mm, advantageously between about 1 ⁇ m and about 500 ⁇ m.
• the thickness of the layer after step (c) is advantageously less than 300 ⁇ m, preferably between about 5 ⁇ m and about 300 ⁇ m, preferably between 5 ⁇ m and 150 ⁇ m.
• said porous layer obtained at the end of step (c) has a specific surface area of between 10 m 2 / g and 500 m 2 / g. Its thickness is advantageously between 1 and 500 ⁇ m, preferably between 4 and 400 ⁇ m.
• the size distribution of the primary particles of the active material P is preferably narrow.
• said agglomerates preferably comprise at least three primary particles.
• the size distribution of said agglomerates is preferably polydisperse.
• the size distribution of the agglomerates is bimodal, that is to say it has two size distribution peaks, these two sizes being called D1 and D2 where D1>D2; the D2 / D1 ratio may for example be between 3 and 7 and preferably between 4 and 6; this prevents the formation of large cavities and ensures good compactness of the mesoporous layer.
• the suspension of nanoparticles can be produced in water or in ethanol, or in a mixture of water and ethanol, or alternatively in a mixture of ethanol and isopropyl alcohol (with less than 3% of Isopropylic alcohol). It does not contain carbon black.
• the suspension used is advantageously characterized by a dry extract. at least 15% and preferably at least 50%.
• the deposition of said coating of electronically conductive material can be carried out by the ALD atomic layer deposition technique, or by immersion of the porous layer in a liquid phase comprising a precursor of said electronically conductive material, followed by the transformation of said precursor into electronically conductive material .
• Said precursor is advantageously a compound rich in carbon, such as a carbohydrate, preferably a polysaccharide, and said transformation into electronically conductive material is in this case carried out by pyrolysis, preferably under an inert atmosphere (for example nitrogen).
• Said electronically conductive material may be carbon. It can be deposited in particular by ALD or by immersion in a liquid phase comprising a carbon precursor.
• the process for manufacturing the porous battery electrode uses an intermediate polymer substrate (such as PET) and results in a so-called “green strip”.
• This raw strip is then separated from its substrate; it then forms plates or sheets (hereinafter the term “plate” is used, regardless of its thickness). After cutting, these plates can be separated from their intermediate substrate.
• These plates are then calcined in order to remove the organic constituents.
• These plates are then sintered in order to consolidate the nanoparticles until a mesoporous ceramic structure is obtained with a porosity of between 25 and 50%.
• Said porous plate obtained in step (c) has a thickness advantageously less than or equal to 5 mm, preferably between approximately 1 ⁇ m and approximately 500 ⁇ m.
• the thickness of the layer after step (c) is advantageously less than 300 ⁇ m, preferably between approximately 5 ⁇ m and approximately 300 ⁇ m, preferably between 5 ⁇ m and 150 ⁇ m.
• a coating of a material an electronic conductor is then deposited on and inside the pores of the porous layer or of the porous plate, preferably mesoporous, as has just been described.
• an electrically conductive sheet is also supplied, covered on both sides with a thin intermediate layer of nanoparticles preferably identical to those constituting the electrode plate or covered on both sides with a thin layer of nanoparticles.
• conductive glue preferably have a thickness of less than 1 ⁇ m.
• This sheet can be a metal strip or a graphite sheet.
• This electrically conductive sheet is then interposed between two plates of porous electrodes obtained previously, respectively between two porous plates obtained after step c).
• the assembly is then heat-pressed so that said intermediate thin layer of nanoparticles is transformed by sintering and consolidates the electrode / substrate / electrode assembly, respectively the porous plate / substrate / porous plate assembly to obtain a sub-assembly rigid and one-piece.
• the bond between the electrode layer, respectively the porous plate, and the intermediate layer is established by atom diffusion; this phenomenon is known by the English term "diffusion bonding".
• This assembly is done with two electrode plates, respectively two porous plates, of the same polarity (typically between two anodes or between two cathodes), and the metal sheet between these two electrode plates, respectively two porous plates, of the same polarity. establishes a parallel connection between them.
• One of the advantages of the second embodiment is that it allows the use of inexpensive substrates such as aluminum foil, copper foil or graphite foil. Indeed, these strips would not withstand the heat treatments for consolidating the deposited layers; sticking them to the electrode plates after their heat treatment also helps prevent oxidation.
• the coating of an electronically conductive material can then advantageously be deposited on and inside the pores of the porous plates. , preferably mesoporous, of the porous plate / substrate / porous plate assembly, as has been described above, in particular when the porous plates used are thick.
• the deposition of said coating of electronically conductive material can be carried out by the ALD atomic layer deposition technique, or by immersion of the porous layer in a liquid phase comprising a precursor of said electronically conductive material, followed by the transformation of said precursor into electronically conductive material .
• This assembly by "diffusion bonding" can be carried out separately as has just been described, and the electrode / substrate / electrode sub-assemblies thus obtained can be used to manufacture a battery.
• This diffusion bonding assembly can also be achieved by stacking and heat-pressing the entire battery structure; in this case, a multilayer stack is assembled comprising a first porous anode layer, its metallic substrate, a second porous anode layer, a solid electrolyte layer, a first cathode layer, its metallic substrate, a second layer of cathode, a new layer of solid electrolyte, and so on.
• This electrode / substrate / electrode sub-assembly can be obtained by bonding the electrode plates to an electrically conductive sheet capable of subsequently acting as an electric current collector, or by depositing and then sintering layers on a substrate capable of acting as electric current collector, in particular a metal substrate.
• the electrode / substrate / electrode sub-assembly on the latter is then deposited the electrolyte film (separator). The necessary cuts are then made to make a battery with several elementary cells, then the sub-assemblies are stacked (typically in "head to tail” mode) and thermocompression is carried out to weld the electrodes together at the level of the solid electrolyte.
• the cutouts necessary to produce a battery with several elementary cells can be made before the deposition on each electrode / substrate / electrode sub-assembly of an electrolyte film (separator), then the sub-assemblies are stacked (typically in “head to tail” mode) and thermocompression is carried out to weld the electrodes together at the level of the electrolyte film (separator).
• thermocompression welding is carried out at a relatively low temperature, which is possible thanks to the very small size of the nanoparticles. As a result, oxidation of the metal layers of the substrate is not observed.
• a conductive adhesive loaded with graphite
• a sol-gel type deposit loaded with conductive particles, or even metal strips, preferably low melting point (eg aluminum); during the thermomechanical treatment (heat pressing) the metal strip can deform by creep and come to make this weld between the plates.
• a porous layer according to the invention made with one of these materials, can perform the cathode function in a battery, and in particular in a lithium ion battery.
• o niobium oxides and mixed oxides of niobium with titanium, germanium, cerium or tungsten and preferably in the group formed by: o Nb 2 C> 5 ⁇ 5, N bi eVVi 6qq 3 ⁇ d , NbieWsOssie with 0 £ x ⁇ 1 and 0 £ d £ 2, LiNb0 3 , o TiNb 2 C> 7 ⁇ 5 , Li w TiNb 2 C> 7 with w30, Tii- x M 1 x Nb 2-y M 2 y C > 7 ⁇ 5 or Li w Tii- x M 1 x Nb 2 - yM 2 y C> 7 ⁇ 5 in which M 1 and M 2 are each at least one element selected from the group consisting of Nb, V, Ta, Fe , Co, Ti, Bi, Sb, As, P, Cr, Mo, W, B, Na, Mg, Ca, Ba, Pb, Al, Zr, Si, Sr,
• the nanoparticles used in the present invention can have a structure of the core-shell type (called “core-shell” in English), and in this case said material P forms the heart.
• the shell may or may not be an ionically conductive dielectric material.
• a porous layer according to the invention, produced with one of these materials, can perform the function of anode in a battery, and in particular in a lithium ion battery.
• an anode material is advantageously used which has a lithium insertion potential greater than 1 V; this allows very fast recharging of the battery.
• the negative electrode can be made of titanate and / or mixed titanium oxides.
• the electrodes are impregnated with an ionic liquid containing a lithium salt.
• the substrate capable of acting as an electric current collector is preferably a noble metal.
• Such a battery has the advantage of being able to operate at high temperature.
• Another object of the present invention is a porous electrode obtainable by the method of manufacturing a porous electrode according to the invention.
• This porous electrode is free of binder. Its porosity is preferably between 20% and 60% by volume, and the average diameter of its pores is less than 50 nm. It can be intended to act as a positive electrode or as a negative electrode in an electrochemical device.
• An electrode according to the invention makes it possible to produce a lithium ion microbattery which has both a high energy density and a high power density.
• This performance is the result of a limited porosity (which increases the energy density), of a very high specific surface (which is favored by the very small size of the primary particles of the electrode, and which leads to the (increase in the exchange surface, which decreases the ionic resistance), the absence of organic binder (the binder can locally mask the access of lithium to the surface of active materials).
• a coating of an electronically conductive material is deposited on and inside the pores of the porous layer. This coating decreases the series resistance of the battery.
• Yet another object of the invention is the use of a method of manufacturing porous electrodes according to the invention for the manufacture of porous electrodes in lithium ion batteries.
• Yet another object of the invention is a method of manufacturing a battery designed to have a capacity not exceeding 1 mAh, implementing the method of manufacturing a porous electrode according to the invention, or implementing a porous electrode according to the invention.
• Said battery is advantageously a lithium ion battery.
• this method of manufacturing a porous electrode can be implemented to manufacture a cathode, and / or to manufacture an anode.
• This method of manufacturing a battery may comprise a step in which said porous electrode is impregnated with an electrolyte, preferably a phase carrying lithium ions selected from the group formed by: an electrolyte composed of at least one solvent aprotic and at least one lithium salt; o an electrolyte composed of at least one ionic liquid and at least lithium salt; o a mixture of at least one aprotic solvent and at least one ionic liquid and at least one lithium salt; o a polymer made ionic conductive by adding at least one lithium salt; and o a polymer rendered ionic conductor by the addition of a liquid electrolyte, either in the polymer phase or in the mesoporous structure,
• an electrode according to the invention makes it possible to realize a lithium ion battery which exhibits both high energy density and high power density. Such a battery is also very reliable. There is no longer any risk of loss of electrical contact between the particles, which gives them excellent cycling life. In addition, the current is perfectly distributed in the electrode, which results from the homogeneity of the size of the pores and the local thickness of the active material, which generate a great homogeneity of the electrical conductivity.
• the battery according to the invention can in particular be designed and sized so as to have a capacity less than or equal to approximately 1 mAh (commonly called a "microbattery").
• microbatteries are designed to be compatible with microelectronics manufacturing processes.
• a final object of the invention is a lithium ion microbattery obtainable by the method of manufacturing a battery according to the invention.
• FIG. 1 to 6 illustrate different aspects and embodiments of the invention, without limiting its scope.
• FIG. 1 shows a diffractogram of primary nanoparticles used for in the suspension before the formation of agglomerates.
• FIG. 2 shows an image obtained by transmission electron microscopy of primary nanoparticles from the same sample as that of FIG. 1.
• FIG. 3 schematically illustrates heat treatment nanoparticles.
• FIG. 4 schematically illustrates nanoparticles after heat treatment, illustrating the phenomenon of “necking”.
• FIG. 5 shows the evolution of the relative capacity of a battery according to the invention as a function of the number of charge and discharge cycles.
• FIG. 6 shows a recharging curve for the same battery: curve A corresponds to the state of charge (right scale), curve B corresponds to the current absorbed (left scale).
• the size of a particle is defined by its largest dimension.
• nanoparticle is understood to mean any particle or object of nanometric size having at least one of its dimensions less than or equal to 100 nm.
• ionic liquid is meant any liquid salt, capable of transporting electricity, which differs from all molten salts by a melting point of less than 100 ° C. Some of these salts remain liquid at room temperature and do not solidify, even at very low temperatures. Such salts are called “ionic liquids at room temperature”.
• mesoporous materials is understood to mean any solid which has within its structure so-called “mesopore” pores having a size intermediate between that of the micropores (width less than 2 nm) and that of the macropores (width greater than 50 nm), namely a size between 2 nm and 50 nm.
• This terminology corresponds to that adopted by IUPAC (International Union for Pure and Applied Chemistry), which is a reference for those skilled in the art.
• nanopore is therefore not used here, even if the mesopores as defined above have nanometric dimensions within the meaning of the definition of nanoparticles, knowing the pores of size smaller than that of the mesopores are called by the those skilled in the art of "micropores”.
• the term “mesoporous electrode” or “mesoporous layer” is understood to mean an electrode, respectively a layer which has mesopores. As will be explained below, in these electrodes or layers the mesopores contribute significantly to the total pore volume; this fact is reflected by the expression “electrode or mesoporous layer of mesoporous porosity greater than X% by volume” used in the description below.
• aggregate means, as defined by IUPAC, a loosely bound assembly of primary particles.
• these primary particles are nanoparticles having a diameter which can be determined by transmission electron microscopy.
• An aggregate of aggregated primary nanoparticles can normally be destroyed (ie reduced to primary nanoparticles) in suspension in a liquid phase under the effect of ultrasound, according to a technique known to those skilled in the art.
• agglomerate means, as defined by IUPAC, a tightly bonded assembly of primary particles or aggregates.
• microbattery is used herein for a battery with a capacity not exceeding 1 mAh.
• microbatteries are designed to be compatible with microelectronics manufacturing processes.
• the process for preparing the porous electrodes according to the invention starts from a suspension of nanoparticles. It is preferable not to prepare these suspensions of nanoparticles from dry nanopowders. They can be prepared by grinding powders or nanopowders in the liquid phase, and / or using ultrasound treatment to deagglomerate the nanoparticles.
• the nanoparticles are prepared in suspension directly by precipitation.
• the synthesis of nanoparticles by precipitation makes it possible to obtain primary nanoparticles of very homogeneous size with a unimodal size distribution i.e. very tight and monodisperse, of good crystallinity and purity.
• the use of these nanoparticles of very homogeneous size and narrow distribution makes it possible to obtain, after deposition, a porous structure of controlled and open porosity.
• the porous structure obtained after depositing these nanoparticles has little, preferably no closed pores.
• the nanoparticles are prepared directly at their primary size by hydrothermal or solvothermal synthesis; this technique makes it possible to obtain nanoparticles with a very narrow size distribution, called “monodisperse nanoparticles".
• the size of these non-aggregated or non-agglomerated nanopowders / nanoparticles is called the primary size. It is typically between 2 nm and 150 nm. It is advantageously between 10 nm and 50 nm, preferably between 10 nm and 30 nm; this promotes during subsequent process steps the formation of an interconnected mesoporous network with electronic and ionic conduction, thanks to the phenomenon of "necking".
• the suspension of monodisperse nanoparticles can be produced in the presence of ligands or organic stabilizers so as to avoid aggregation, or even agglomeration, of the nanoparticles.
• Binders can also be added to the suspension of nanoparticles to facilitate the production of deposits or bare bands, in particular thick deposits without cracks.
• This suspension of monodisperse nanoparticles can be purified to remove any potentially troublesome ions. Depending on the degree of purification it can then be specially treated to form aggregates or agglomerates of a controlled size. More precisely, the formation of aggregates or agglomerates can result from the destabilization of the suspension caused in particular by ions, by the increase in the dry extract of the suspension, by changing the solvent of the suspension, by the addition of destabilizing agent. If the suspension has been completely purified it is stable, and ions are added to destabilize it, typically in the form of a salt; these ions are preferably lithium ions (preferably added in the form of LiOH).
• One of the essential aspects for the manufacture of electrodes according to the invention is to have good control of the size of the primary particles of electrode materials and their degree of aggregation or agglomeration.
• the stabilization of the suspension of nanoparticles occurs after the formation of agglomerates, the latter will remain in the form of agglomerates; the suspension obtained can be used to make mesoporous deposits.
• a mesoporous layer having a mean diameter of the mesopores between 2 nm and 50 nm.
• the porous electrode layer can be deposited by the ink-jet printing process (called “ink-jet” in English) or by a coating process, and in particular by the coating process by dipping (called “dip-coating” in English), by roller coating (called “roll coating” in English), by curtain coating (called “curtain coating” in English), by coating through a slot-shaped die (called “slot-die” in English), or by scraping (called “doctor blade” in English), and this from a fairly concentrated suspension comprising aggregates or agglomerates nanoparticles of the active material P.
• ink-jet ink-jet
• a coating process in particular by the coating process by dipping (called “dip-coating” in English), by roller coating (called “roll coating” in English), by curtain coating (called “curtain coating” in English), by coating through a slot-shaped die (called “slot-die” in English), or by scraping (called “doctor blade” in English), and this from a fairly concentrated suspension comprising aggregate
• the porous electrode layer can also be deposited by electrophoresis, but a less concentrated suspension is then used advantageously containing agglomerates of nanoparticles of the active material P.
• the deposition processes of aggregates or agglomerates of nanoparticles electrophoretically, by the coating process by dipping, by ink jet, by roller coating, by curtain coating, by coating through a shaped die slitting or scraping processes are simple, safe, easy to implement, to industrialize and to obtain a final homogeneous porous layer.
• Electrophoretic deposition enables uniform deposition of layers over large areas with high deposition rates.
• the coating techniques in particular those mentioned above, make it possible to simplify the management of the baths compared to the electrophoretic deposition techniques because the suspension does not become depleted of particles during the deposition. Inkjet printing deposition allows for localized deposits.
• Porous thick layer layers can be produced in a single step by roller coating, by curtain coating, by coating through a slot (called “slot die coating” in English), or by scraping (i.e. with a doctor blade).
• colloidal suspensions in water and / or ethanol and / or IPA and their mixtures are more fluid than those obtained in NMP. It is thus possible to increase the dry extract of the suspension in agglomerates of nanoparticles. These agglomerates preferably have sizes less than or equal to 200 nm and are of polydisperse sizes, or even with two populations of different sizes.
• a layer of a suspension of nanoparticles is deposited on a substrate, by any suitable technique, and in particular by a method selected from the group formed by: electrophoresis, a printing process and preferably inkjet printing or flexographic printing, a coating and coating process preferably by doctor blade, roller, curtain, dipping, or through a slot-shaped die.
• the suspension is typically in the form of an ink, that is to say a fairly fluid liquid, but can also have a pasty consistency.
• the deposition technique and the conduct of the deposition process must be compatible with the viscosity of the suspension, and vice versa.
• the deposited layer will then be dried.
• the layer is then consolidated to obtain the desired ceramic mesoporous structure.
• This consolidation will be described below. It can be carried out by heat treatment, by heat treatment preceded by mechanical treatment, and possibly by thermomechanical treatment, typically thermocompression. During this thermomechanical or thermal treatment, the electrode layer will be free of any constituent and organic residue (such as the liquid phase of the suspension of nanoparticles and any surfactant products): it becomes an inorganic layer (ceramic).
• the consolidation of a plate is preferably carried out after its separation from its intermediate substrate, because the latter could be degraded during this treatment.
• the layers of electrodes are each deposited on a substrate capable of acting as an electric current collector. Layers comprising the suspension of nanoparticles or agglomerates of nanoparticles can be deposited on one side or on both sides thereof, by the deposition techniques indicated above.
• the substrate serving as a current collector in batteries employing porous electrodes according to the invention can be metallic, for example a metal strip (i.e. a laminated metal sheet).
• the substrate is preferably chosen from strips of tungsten, molybdenum, chromium, titanium, tantalum, stainless steel, or an alloy of two or more of these materials. Less noble substrates such as copper or nickel may receive a conductive and protective coating against oxidation.
• the metal foil can be coated with a layer of noble metal, in particular chosen from gold, platinum, palladium, titanium or alloys predominantly containing at least one or more of these metals, or with a layer of material.
• ITO type conductor which has the advantage of also acting as a diffusion barrier.
• this substrate capable of acting as an electric current collector must withstand the heat treatment conditions of the deposited layer, and the operating conditions within the battery cell. As such, copper and nickel are suitable in contact with the cathode material; they risk oxidizing at the anode.
• the electrophoresis process (especially in water) can be used.
• the substrate is subjected to an electrochemical polarization which leads either to its oxidation or to its dissolution in the suspension of nanoparticles.
• only substrates which do not exhibit anodization and / or corrosion phenomena can be used. This is particularly the case with stainless steel and noble metals.
• the nanopowders and / or agglomerates are crystallized, obtained by hydrothermal or solvothermal synthesis with the right phase and crystalline structure, then it is possible to use consolidation heat treatments in a controlled atmosphere, which will allow the use of less noble substrates. like nickel, copper, aluminum, and due to the very small size of the primary particles obtained by hydrothermal synthesis, it is also possible to reduce the temperature and / or the duration of the consolidation heat treatment to values close to 350 - 500 ° C , which also makes it possible to widen the choice of substrates.
• these less noble substrates must resist the heat treatment making it possible to remove the organic additives possibly contained in the suspension of nanoparticles used such as ligands, stabilizers, binders or residual organic solvents (debinding), this heat treatment being advantageously carried out under oxidizing atmosphere.
• These substrates capable of acting as an electric current collector can optionally be covered with a thin film of conductive oxide.
• This oxide may have the same composition as the electrode.
• These thin films can be produced by sol-gel. This oxide-based interface helps limit corrosion of the substrate and provides a better bonding base for the electrode with the substrate.
• the liquid electrolytes which come to impregnate the porous electrode are in direct contact with the substrate capable of acting as a current collector.
• substrates capable of acting as a current collector ie metal substrates and polarized at very anodic potentials for the cathode and very cathodic for the anode, these electrolytes are liable to induce a dissolution of the current collector.
• parasitic reactions can degrade the life of the battery and accelerate its self-discharge.
• substrates capable of acting as a current collector such as aluminum current collectors are used at the cathode in all lithium ion batteries.
• Aluminum has the particularity of anodizing at very anodic potentials, and the oxide layer thus formed on its surface protects it from dissolution.
• aluminum has a melting point of close to 600 ° C and cannot be used for the manufacture of batteries according to the invention, if the consolidation treatments of the electrodes risk melting the current collector.
• a titanium strip is advantageously used as a current collector at the cathode.
• the titanium strip will, like aluminum, anodize and its oxide layer will prevent any parasitic reactions of dissolution of the titanium in contact with the liquid electrolyte.
• entirely solid electrodes according to the invention can be produced directly on this type of strip.
• Stainless steel can also be used as a current collector, especially when it contains titanium or aluminum as an alloying element, or when it has a thin layer of protective oxide on the surface.
• substrates serving as current collector can be used such as less noble metal strips covered with a protective coating, allowing to avoid the possible dissolution of these strips induced by the presence of electrolytes in contact with them.
• These less noble metal strips can be copper, nickel or metal alloy strips such as stainless steel strips, Fe-Ni alloy, Be-Ni-Cr alloy, alloy Ni-Cr or Ni-Ti alloy.
• the coating that can be used to protect the substrates serving as current collectors can be of different types. He can be :
• a dense, defect-free metallic thin layer such as a metallic thin layer of gold, titanium, platinum, palladium, tungsten or molybdenum.
• metallic thin layer can be used to protect current collectors because they have good conduction properties and can withstand heat treatments during the subsequent electrode fabrication process.
• This layer can in particular be produced by electrochemistry, PVD, CVD, evaporation, ALD;
• a thin layer of carbon such as diamond carbon, graphic, deposited by ALD, PVD, CVD or by inking of a sol-gel solution making it possible to obtain, after heat treatment, an inorganic phase doped with carbon to make it conductive, • a layer of conductive or semiconductor oxides, such as a layer of ITO (indium tin oxide) only deposited on the cathode substrate because the oxides are reduced at low potentials;
• a thin layer of carbon such as diamond carbon, graphic, deposited by ALD, PVD, CVD or by inking of a sol-gel solution making it possible to obtain, after heat treatment, an inorganic phase doped with carbon to make it conductive
• a layer of conductive or semiconductor oxides such as a layer of ITO (indium tin oxide) only deposited on the cathode substrate because the oxides are reduced at low potentials;
• a layer of conductive nitrides such as a layer of TiN only deposited on the cathode substrate because the nitrides insert lithium at low potentials.
• the coating that can be used to protect the substrates serving as current collectors must be electronically conductive so as not to interfere with the operation of the electrode subsequently deposited on this coating, by making it too resistive.
• the maximum dissolution currents measured on the substrates which can act as a current collector, at the operating potentials of the electrodes, expressed in pA / cm 2 must be 1000 times lower than the surface capacities of the electrodes expressed in pAh / cm 2 .
• the shrinkage generated by the consolidation can lead either to the cracking of the layers, or to a shear stress at the level of the interface between the substrate (which is fixed dimension) and the ceramic electrode. When this shear stress exceeds a threshold, the layer detaches from its substrate.
• the thickness of the electrodes by a succession of deposition - sintering operations.
• This first variant of the first embodiment of the deposition of the layers gives a good result, but is not very productive.
• layers of greater thickness are deposited on both sides of a perforated substrate.
• the perforations must be of sufficient diameter so that the two layers of the front and back are in contact at the perforations.
• the nanoparticles and / or agglomerates of nanoparticles of electrode material in contact through the perforations in the substrate weld together, forming an attachment point (weld point between the deposits on the two faces). This limits the loss of adhesion of the layers to the substrate during the consolidation steps.
• binders and dispersants can be added by a heat treatment, preferably under an oxidizing atmosphere, such as by debinding, during a sintering treatment or during a heat treatment carried out prior to the sintering treatment.
• the electrode layers are not deposited on a substrate capable of acting as an electric current collector, but on an intermediate, temporary substrate.
• a substrate capable of acting as an electric current collector
• These thick layers are deposited for example by a coating process, preferably with a doctor blade (a technique known in English under the term “doctor blade” or “tape casting") or through a slot-shaped die (in English " slot-die ”).
• Said intermediate substrate may be a polymeric sheet, for example poly (ethylene terephthalate), abbreviated PET.
• these layers do not crack, especially when drying occurs after the separation of the layer obtained in step (b) from its intermediate substrate.
• a stack of three layers is then made, namely two plates of electrodes of the same polarity separated by an electrically conductive foil capable of acting as an electric current collector, such as a metal foil or a graphite foil.
• This stack is then assembled by a thermomechanical treatment, comprising pressing and a heat treatment, preferably carried out simultaneously.
• the interface may be coated with a layer allowing electronically conductive bonding.
• This layer can be a sol-gel layer (preferably of the type allowing the chemical composition of the electrodes to be obtained after heat treatment) possibly loaded with particles of an electronically conductive material, which will make a ceramic weld between the mesoporous electrode and the sheet.
• metallic This layer can also consist of a thin layer of non-sintered electrode nanoparticles, or of a thin layer of a conductive adhesive (loaded with graphite particles for example), or even a metallic layer of a metal to low melting point.
• said electrically conductive sheet is metallic, it is preferably a laminated sheet, ie obtained by rolling. Rolling can optionally be followed by a final annealing, which can be a softening annealing (total or partial) or recrystallization, depending on the terminology of metallurgy. You can also use a leaf electrochemically deposited, for example an electrodeposited copper foil or an electroplated nickel foil.
• a ceramic electrode without organic binder, mesoporous, located on either side of a metal substrate serving as an electronic current collector.
• the electrodes according to the invention can be manufactured from suspensions of nanoparticles, using known coating techniques. These techniques which can be used are strip casting and coating techniques, such as roller coating, doctor blade coating, coating through a slot-shaped die, curtain coating, roller coating. You can also use soaking.
• the dry extract of the suspension is advantageous for the dry extract of the suspension to be greater than 20%, and preferably greater than 40%; this decreases the risk of cracking on drying.
• Printing techniques can also be used, such as flexographic techniques, inkjet printing.
• Electrophoresis can also be used.
• the method according to the invention advantageously uses the electrophoresis of suspensions of nanoparticles as a technique for depositing porous, preferably mesoporous, electrode layers.
• the method of depositing layers of electrodes from a suspension of nanoparticles is known as such (see for example EP 2 774 194 B1).
• the substrate can be metallic, for example a metallic foil.
• the substrate serving as a current collector in batteries employing porous electrodes according to the invention is preferably chosen from strips of titanium, copper, stainless steel or molybdenum.
• a stainless steel sheet with a thickness of 5 ⁇ m can be used as the substrate.
• the metal foil can be coated with a layer of noble metal, in particular chosen from gold, platinum, palladium, titanium or alloys predominantly containing at least one or more of these metals, or with a layer of material.
• ITO type conductor which has the advantage of also acting as a diffusion barrier.
• a layer, preferably a thin layer, of an electrode material is deposited on the metal layer; this deposit must be very thin (typically a few tens of nanometers, and more generally between 10 nm and 100 nm). It can be carried out by a sol-gel process.
• LiMn 2 0 4 can be used for a porous LiMn 2 0 4 cathode.
• a counter electrode is placed in the suspension and a voltage is applied between the conductive substrate and said counter electrode.
• the electrophoretic deposition of the aggregates or agglomerates of nanoparticles is carried out by galvanostatic electrodeposition in pulsed mode; high frequency current pulses are applied, this avoids the formation of bubbles on the surface of the electrodes and the variations of the electric field in the suspension during the deposition.
• the thickness of the electrode layer thus deposited by electrophoresis, preferably by galvanostatic electrodeposition in pulsed mode is advantageously less than 10 ⁇ m, preferably less than 8 ⁇ m, and is even more preferably between 1 ⁇ m and 6 ⁇ m.
• carbon black nanoparticles can be added to the suspension in order to improve the electronic conduction of the deposit before consolidation. These carbon black nanoparticles will be oxidized away during the consolidation heat treatment.
• aggregates or agglomerates of nanoparticles can be deposited by the dip coating process, regardless of the chemical nature of the nanoparticles used. This deposition process is preferred when the nanoparticles used have little or no electric charge.
• the step of depositing by dipping the aggregates or agglomerates of nanoparticles followed by the step of drying the resulting layer are repeated as necessary.
• at least one organic additive such as ligands, stabilizers, thickeners, binders or organic solvents. residuals.
• the dried layers can be consolidated by a pressing and / or heating step (heat treatment).
• this treatment leads to a partial coalescence of the primary nanoparticles in the aggregates, or agglomerates, and between neighboring aggregates or agglomerates; this phenomenon is called “necking” or “neck formation”. It is characterized by the partial coalescence of two particles in contact, which remain separated but connected by a neck (constricted); this is illustrated schematically in Figures 3 and 4. Lithium ions and electrons are mobile within these necks and can diffuse from particle to particle without encountering grain boundaries.
• the nanoparticles ( Figure 3) are welded together to ensure the conduction of electrons from one particle to another ( Figure 4).
• a continuous mesoporous film is formed from the primary nanoparticles forming a three-dimensional network with high ionic mobility and electron conduction; this network comprises interconnected pores, preferably mesopores.
• the temperature necessary to obtain “necking” depends on the material; taking into account the diffusive nature of the phenomenon which leads to necking, the duration of the treatment depends on the temperature. This process can be called sintering; depending on its duration and temperature, a more or less pronounced coalescence (necking) is obtained, which has repercussions on the porosity. It is thus possible to go down to 30% (or even 25%) of porosity while maintaining a perfectly homogeneous channel size.
• the heat treatment can also be used to eliminate the organic additives possibly contained in the suspension of nanoparticles used, such as ligands, stabilizers, binders or residual organic solvents.
• an additional heat treatment under an oxidizing atmosphere, can be carried out to remove these organic additives possibly contained in the suspension of nanoparticles used.
• This additional heat treatment is advantageously carried out on the porous layer separated from its intermediate substrate, when such a substrate is used.
• This additional heat treatment is advantageously carried out before the consolidation treatment of step c) making it possible to obtain a porous, preferably mesoporous, layer.
• a coating of an electronically conductive material is deposited on and inside the pores of said porous layer.
• the method according to the invention which necessarily involves a step of depositing agglomerated nanoparticles of electrode material (active material), causes the nanoparticles to “weld” naturally to each other to generate , after consolidation such as annealing, a porous, rigid, three-dimensional structure, without organic binder; this porous layer, preferably mesoporous, is perfectly suited to the application of a surface treatment, by gas or liquid, which goes into the depth of the open porous structure of the layer.
• this deposit is carried out by a technique allowing an encapsulating coating (also called “conformal deposit”), ie a deposit which faithfully reproduces the atomic topography of the substrate on which it is applied, and which goes deep into the porosity network. open the layer.
• Said electronically conductive material may be carbon.
• ALD Atomic Layer Deposition
• CSD Chemical Solution Deposition
• the techniques of ALD (Atomic Layer Deposition) or CSD (Chemical Solution Deposition), known as such, may be suitable. They can be implemented on the porous layers after manufacture, before the deposition of the separator particles and before the assembly of the cell.
• the ALD deposition technique is carried out layer by layer, by a cyclic process, and makes it possible to produce an encapsulating coating which faithfully reproduces the topography of the substrate; the coating lines the entire surface of the electrodes.
• This coating coating typically has a thickness of between 1 nm and 5 nm.
• the deposition by ALD is carried out at a temperature typically between 100 ° C and 300 ° C. It is important that the layers are free from organic matter: they must not contain any organic binder, any residues of stabilizing ligands used to stabilize the suspension must have been removed by purification of the suspension and / or during the heat treatment of the suspension. layer after drying. Indeed, at the temperature of the ALD deposit, the organic materials forming the organic binder (for example the polymers contained in the electrodes produced by ink tape casting) risk decomposing and will pollute the ALD reactor. Furthermore, the presence of residual polymers in contact with the particles of electrode active material can prevent the ALD coating from coating all of the surfaces of the particles, which affects its effectiveness.
• the CSD deposition technique also makes it possible to produce an encapsulating coating with a precursor of the electronically conductive material which faithfully reproduces the topography of the substrate; it covers the entire surface of the electrodes.
• This coating coating typically has a thickness of less than 5 nm, preferably between 1 nm and 5 nm. It must then be transformed into an electronically conductive material. In the case of a carbon precursor, this will be done by pyrolysis, preferably under inert gas (such as nitrogen).
• the diameter D50 of the primary particles of electrode material is at least 10 nm in order to prevent the conductive layer from blocking the open porosity of the electrode layer.
• the electrolyte is not part of the present invention, but it is useful to mention it here because it is necessary to form the battery cell.
• the electrode according to the invention does not contain organic compounds. This absence of organic compounds coupled to a mesoporous structure promotes wetting by an electrolyte which conducts lithium ions.
• This electrolyte can then be chosen without distinction from the group formed by: an electrolyte composed of aprotic solvents and lithium salts, an electrolyte composed of ionic liquids or ionic polyliquids and lithium salts, a mixture of aprotic solvents and ionic liquids or ionic polyliquids and lithium salts, an ionically conductive polymer containing lithium salts, an ionically conductive polymer.
• Said ionic liquids can be salts molten at room temperature (these products are known under the designation RTIL, Room Temperature Ionie Liquid), or ionic liquids which are solid at room temperature. These ionic liquids which are solid at room temperature must be heated in order to liquefy them in order to impregnate the electrodes; they solidify in the electrode. Said ionically conductive polymer can be melted to be mixed with the lithium salt and this molten phase can then be impregnated into the mesoporosity of the electrode.
• RTIL Room Temperature Ionie Liquid
• said polymer can be a liquid at room temperature, or else a solid, which is then heated to make it liquid with a view to its impregnation in the mesoporous electrode.
• the cathode when the lithium ion battery must operate at high temperature, one of the materials listed above is advantageously used for the cathode as the material P from those which does not contain manganese, such as LiFePCU or UC0PO4.
• the anode is in this case advantageously a titanate, a mixed oxide of titanium and niobium or a derivative of a mixed oxide of titanium and niobium, and the cell is impregnated with an ionic liquid comprising a lithium salt. If said ionic liquid contains sulfur atoms, it is preferred that the substrate is a noble metal.
• Figure 1 shows a typical X-ray diffractogram of the LUTisO ⁇ nanopowder used in the suspension
• Figure 2 shows a picture obtained by transmission electron microscopy of these primary nanoparticles.
• This material is deposited on a metal substrate, heat treated (sintered) and covered with a layer of an electronically conductive material a few nanometers thick; this layer is called here “nanocoating”.
• This nanocoating is preferably carbon.
• This carbon nanocoating can be produced by impregnation with a liquid phase rich in carbon, which is then pyrolyzed under nitrogen, or else by ALD deposition. These anodes insert lithium at a potential of 1.55 V, are very powerful and allow ultra-fast recharging.
• a mesoporous anode is manufactured according to the invention for a lithium ion battery with a material P which is Til ⁇ lb2C> 7 or Li w Tii- x M 1 x Nb2-yM 2 yC > 7, wherein M 1 and M 2 are each at least one element selected from the group consisting of Nb, V, Ta, Fe, Co, Ti, Bi, Sb, As, P, Cr, Mo, W, B, Na, Mg, Ca, Ba, Pb, Al, Zr, Si, Sr, K, Cs and Sn.
• M 1 and M2 can be identical or different from each other, and in which 0 £ w £ 5, 0 £ x £ 1, 0 £ y £ 2.
• This layer is deposited on a metal substrate, sintered and covered of an electronically conductive nanocoating, which is advantageously carbon, deposited as described in relation to the previous embodiment.
• a mesoporous anode is manufactured according to the invention for a lithium ion battery with a material P which is Nb 2 0s ⁇ 5 or NbisWi6093 ⁇ 5 or Nbi6Ws055 ⁇ 5 with 0 £ x ⁇ 1 and 0 £ d £ 2, or La x Tii-2xNb2 + x C> 7 where 0 ⁇ x ⁇ 0.5; or Tii- x Ge x Nb 2-y M 1 y 0 7 ⁇ z O u Li w Tii- x Ge x Nb 2-y M 1 y 0 7 ⁇ z or Tii- x Ce x Nb2- y M 1 y C> 7 ⁇ z O u du Li w Tii- x Ce x Nb 2-y M 1 y 0 7 ⁇ z in which M 1 is at least one element selected from the group consisting of Nb, V, Ta , Fe, Co, Ti, Bi, S
• a mesoporous anode is manufactured according to the invention for a lithium ion battery with a material P which is TiNb 2 0 7-z M 3 z or Li w Tii- x M 1 x Nb 2 -yM 2 y0 7-z M 3 z wherein M 1 and M2 are each at least one member selected from the group consisting of Nb, V, Ta, Fe, Co, Ti, Bi, Sb, As, P, Cr, Mo, W, B, Na, Mg, Ca, Ba, Pb, Al, Zr, Si, Sr, K, Cs and Sn.
• M 1 and M 2 can be identical or different from each other.
• M 3 is at least one halogen and z £ 0.3.
• this layer is deposited on a metallic substrate, sintered and covered with a nanocoating, which may be carbon, deposited as described above. These anodes are very powerful and are capable of quick recharges.
• a mesoporous anode is manufactured according to the invention for a lithium ion battery with a material P which is T1O2 or LiSiTON; the manufacture is carried out as described in relation to the other embodiments. These electrodes are very powerful and are capable of rapid recharges.
• a mesoporous cathode according to the invention is manufactured for a lithium ion battery with a material P which is LiMn 2 0 4 ; these nanoparticles can be obtained by hydrothermal synthesis using the procedures described in the article “One pot hydrothermal synthesis and electrochemical characterization of Lii + x Mn 2-y 0 4 spinel structured compounds”, published in the journal Energy Environ.
• a battery according to the invention formed by:
• a mesoporous electrolytic separator (50% porosity) comprising U3PO4.
• the electrode substrates were 316L stainless steel.
• the ionic impregnation liquid was a mixture of 0.7 M.
• Figure 5 shows the evolution of the relative capacity of a battery according to the invention as a function of the number of charge and discharge cycles; each discharge was carried out to a depth of 100% of the battery capacity. It is observed that there is no loss of the relative capacity of the battery; the battery according to the invention has an excellent lifespan in terms of charge-discharge cycles.
• Figure 6 shows a recharging curve for this battery. We see that we can recharge 80% of the battery's capacity in just under 5 minutes; this rapid recharging capacity is of enormous application interest.

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• 2020
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