WO2023187498A1 - Batteries et leurs procédés de fabrication - Google Patents

Batteries et leurs procédés de fabrication Download PDF

Info

Publication number
WO2023187498A1
WO2023187498A1 PCT/IB2023/051912 IB2023051912W WO2023187498A1 WO 2023187498 A1 WO2023187498 A1 WO 2023187498A1 IB 2023051912 W IB2023051912 W IB 2023051912W WO 2023187498 A1 WO2023187498 A1 WO 2023187498A1
Authority
WO
WIPO (PCT)
Prior art keywords
electrolyte
solid
conductive housing
lithium
battery
Prior art date
Application number
PCT/IB2023/051912
Other languages
English (en)
Inventor
Gaurav Jain
Prabhakar A. Tamirisa
Kaimin Chen
Original Assignee
Medtronic, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US18/114,027 external-priority patent/US20230318097A1/en
Application filed by Medtronic, Inc. filed Critical Medtronic, Inc.
Publication of WO2023187498A1 publication Critical patent/WO2023187498A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/056—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
    • H01M10/0561—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of inorganic materials only
    • H01M10/0562—Solid materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/056—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
    • H01M10/0564—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of organic materials only
    • H01M10/0565—Polymeric materials, e.g. gel-type or solid-type
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/056—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
    • H01M10/0564—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of organic materials only
    • H01M10/0566—Liquid materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/116—Primary casings; Jackets or wrappings characterised by the material
    • H01M50/124—Primary casings; Jackets or wrappings characterised by the material having a layered structure
    • H01M50/1243—Primary casings; Jackets or wrappings characterised by the material having a layered structure characterised by the internal coating on the casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/545—Terminals formed by the casing of the cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/14—Cells with non-aqueous electrolyte
    • H01M6/16—Cells with non-aqueous electrolyte with organic electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/14—Cells with non-aqueous electrolyte
    • H01M6/18—Cells with non-aqueous electrolyte with solid electrolyte
    • H01M6/181—Cells with non-aqueous electrolyte with solid electrolyte with polymeric electrolytes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/14—Cells with non-aqueous electrolyte
    • H01M6/18—Cells with non-aqueous electrolyte with solid electrolyte
    • H01M6/185—Cells with non-aqueous electrolyte with solid electrolyte with oxides, hydroxides or oxysalts as solid electrolytes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/22—Immobilising of electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2300/00—Electrolytes
    • H01M2300/0017—Non-aqueous electrolytes
    • H01M2300/0065—Solid electrolytes
    • H01M2300/0068—Solid electrolytes inorganic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2300/00—Electrolytes
    • H01M2300/0085—Immobilising or gelification of electrolyte

Definitions

  • the present disclosure relates generally to electrochemical batteries.
  • the present disclosure further relates to non-neutral case primary and secondary batteries that include one or more features that reduce or prevent electrolyte contact with the case and/or header of the battery.
  • battery cases are constructed to be at non-neutral polarity.
  • lithium primary and lithium-ion secondary batteries may have cases that are at a negative polarity.
  • the case being at a non-neutral polarity may promote the plating of lithium metal on unwanted regions of the battery, such as regions of the case and/or header. Unwanted lithium plating may decrease the life of the battery and/or reduce the capacity of the battery. As such, further improvements to batteries that have cases at non-neutral polarities are desired.
  • the present disclosure describes, in one aspect, a battery.
  • the battery includes a conductive housing having an inner surface, an outer surface, a proximal end, and a distal end.
  • the battery also includes a header assembly disposed at the proximal end.
  • the header assembly includes a header cap where the header cap has an inner surface.
  • the battery further includes an electrode assembly disposed within the conductive housing proximate to the inner surface and between the proximal end and the distal end of the conductive housing.
  • the electrode assembly includes at least two electrodes including a cathode and an anode, an interelectrode region defining and interelectrode volume, and a solid-state electrolyte.
  • the present disclosure describes a battery.
  • the battery includes a conductive housing having an inner surface, an outer surface, a proximal end, and a distal end. At least a portion of the inner surface of the conductive housing is coated with an electrically insulative coating.
  • the battery also includes a header assembly disposed at the proximal end.
  • the header assembly includes a header cap where the header cap has an inner surface.
  • the battery further includes an electrode assembly disposed within the conductive housing proximate to the inner surface and between the proximal end and the distal end of the conductive housing.
  • the electrode assembly includes at least two electrodes including a cathode and an anode, an interelectrode region defining and interelectrode volume, and an electrolyte.
  • the present disclosure describes a battery.
  • the battery includes a conductive housing having an inner surface, an outer surface, a proximal end, and a distal end.
  • the battery also includes a header assembly disposed at the proximal end.
  • the battery further includes an electrode assembly disposed within the conductive housing proximate to the inner surface and between the proximal end and the distal end of the conductive housing.
  • the electrode assembly includes at least two electrodes including a cathode and an anode, an interelectrode region defining and interelectrode volume, and a solid-state electrolyte.
  • the solid-state electrolyte is prepared by mixing an electrolyte pre-cursor to form a solid-state precursor mixture; adding a volume of the solid-state precursor mixture to the electrode assembly, the volume being the same or less than the void volume; and forming the solid-state electrolyte, the solid-state electrolyte being confined to the void volume.
  • the present disclosure describes a method, the method includes constructing a conductive housing having an inner surface, a proximal end and a distal end. The method further includes coupling a header assembly to the proximal end. The method further includes preparing an electrode assembly comprising at least two electrodes comprising an anode and a cathode, an interelectrode region, and a solid-state electrolyte. The method further includes disposing the electrode assembly within the conductive housing proximate the inner surface and between the proximal end and the distal end of the conductive housing.
  • the cathode includes pores.
  • the cathode pores and the interelectrode volume define a void volume and the solid-state electrolyte is confined to the void volume.
  • the interactome region includes a porous separator.
  • FIG. 1 A is a schematic cross-sectional view of a battery of an illustrative embodiment.
  • FIG. IB is a schematic cross-sectional view of an electrode assembly of the battery in FIG. 1A.
  • FIG. 2 is a flow diagram illustrating an overview of a solid-state electrolyte deposition method consistent with embodiments of the present disclosure.
  • polymer and polymeric material include, but are not limited to, organic homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof.
  • polymer shall include all possible geometrical configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetries.
  • the term “or” is generally employed in its usual sense including “and/or” unless the content clearly dictates otherwise.
  • the term “and/or” means one or all of the listed elements or a combination of any two or more of the listed elements.
  • the recitations of numerical ranges by endpoints include all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc. or 10 or less includes 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). Where a range of values is “up to” or “at least” a particular value, that value is included within the range.
  • any direction referred to here, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of an actual device or system or use of the device or system. Devices or systems as described herein may be used in a number of directions and orientations.
  • the battery case is constructed to be at a non-neutral polarity (e.g., negative or positive polarity). This may result in the plating of lithium metal on the case and/or header cap, outside the electrode assembly region.
  • the battery includes one or more features that reduces or prevents lithium plating in unwanted regions of the battery. Such features may include features that reduce or prevent the movement of the electrolyte and thus reduce or prevent the electrolyte from contacting certain regions of the non-neutral battery case.
  • Embodiments of the present disclosure may be applied to a primary battery, such as a lithium battery.
  • Primary batteries are single use batteries that cannot be recharged.
  • Embodiments of the present disclosure may be applied to a secondary battery, such as a lithium-ion battery. Secondary batteries are batteries that can be recharged and reused.
  • FIGS. 1A-1B an illustrative embodiment of a battery that includes one or more of the above-described features is depicted.
  • FIG. 1 A is a cross-sectional view of a battery 10 consistent with the present disclosure.
  • the battery 10 is generally configured to store electrical energy in the form of chemical energy.
  • the battery 10 is also generally configured to supply electrical power to a device to which it may be operably coupled.
  • FIG. 1 A depicts the cross section of a cylindrical battery.
  • one or more embodiments of the present disclosure may be applied to a prismatic battery configuration, a button/coin battery configuration, and a pouch battery configuration.
  • the battery 10 and the description of illustrative embodiments refer to a battery with a single cell.
  • the term “cell” refers to a single voltaic/galvanic cell that includes an anode, a cathode, and an electrolyte.
  • one or more of the embodiments of the present disclosure may be applied to a battery that include two or more cells connected in series or in parallel.
  • the battery 10 includes a conductive housing 20 that has an inner surface 22, and outer surface 24, a proximal end 26, and a distal end 28.
  • a header assembly 30 is coupled to the proximal end 26 of the conductive housing 20.
  • An electrode assembly 40 (as shown in FIG. IB) is disposed within the conductive housing 20 proximate to the inner surface 22 between the proximal end 26 and the distal end 28 of the conductive housing 20.
  • the conductive housing 20 is generally configured to contain the electrode assembly 40 of the battery 10.
  • the conductive housing 20 is generally configured to protect the electrode assembly 40 of the battery 10.
  • the conductive housing 20 is also generally configured to serve as a path for current to complete the circuit of the battery.
  • a portion of the conductive housing 20 is electrically conductive, that is, the conductive housing 20 is at a non-neutral polarity.
  • the term “polarity” refers to electrical polarity and should be understood to represent electrical potential.
  • the conductive housing 20 is at a negative polarity.
  • the conductive housing 20 is at a positive polarity.
  • the conductive housing 20 may be made of any material or combination of materials that as a whole are able to conduct electricity.
  • the material includes conductive materials and non-conductive materials.
  • the material includes only conductive materials.
  • the conductive housing 20 may be made of a material that includes a metal, a polymer, or a combination thereof. Examples of metals that may be included in the conductive housing 20 material include, but are not limited to, titanium, silver, copper, gold, aluminum, zinc, nickel, iron, platinum, lead, antimony, palladium, platinum, silicon, various oxidation states thereof, and combinations thereof.
  • the conductive housing 20 may be made of material that includes a metal alloy.
  • Suitable example metal alloys include, but are not limited to, steel (e.g., iron-carbon alloy) and alloy steel such as, steel-chrome, steel-nickel, steel-magnesium, stainless-steel (e.g., 300 series and/or 400 series), tungsten-steel, chromium-molybdenum-steel, nickel-chromium-molybdenum-steel, chromium- vanadium-steel, and combinations thereof; various bronze alloys (e.g., copper-tin alloys) such as aluminum-bronze, copper-bronze, copper-aluminum-bronze, phosphor-bronze, and combinations thereof; various brass (e.g., copper-zinc alloys) alloys such as tin-brass (e.g., Admiralty brass), yellow brass, red brass, and combinations thereof; aluminum alloys such as aluminum-copper, aluminum- copper-magnesium, aluminum-silicon, aluminum-bronze, and combinations thereof; bery
  • the conductive housing 20 material may include one or more conductive polymers.
  • Conductive polymers may be organic, inorganic, or a mixture thereof. Polymers may either be inherently conductive or display conductive properties upon doping. Doping refers to exposing a polymer, either during synthesis or after synthesis, to one or more reagents that impart conductive properties to the polymer. For example, doping may include exposing a polymer to oxidizing reagents, reducing agents, and/or electron-accepting reagents.
  • organic conductive polymers include, but are not limited to, transpolyacetylene (inherent or doped), polyphenylene vinylene (inherent or doped), polypyrrole (inherent or doped), polythiophene (inherent or doped), poly(3,4-ethylenedioxydthiophene) (inherent or doped), polyaniline (inherent or doped), polycarbazoles (inherent or doped), polyindole (inherent or doped), polyazepine (inherent or doped), polyfluorene (inherent or doped), polypyrene (inherent or doped), polyazulene (inherent or doped), polynaphthalene (inherent or doped), poly(l,6-heptadiyne) (doped), polyethylene succinate (doped), polyethylene oxide (doped), polypropylene oxide (doped), polyvinyl acetate (doped), and poly
  • a portion of inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • the conductive housing insulative coating 29 may be any coating that is electrically non-conductive, that is, has a high resistivity.
  • the conductive insulative coating 29 is non-porous and unable to react with lithium ion (e.g., unable to intercalate lithium ions).
  • the conductive housing insulative coating 29 may be a polymer or an inorganic compound.
  • the conductive housing insulative coating 29 may function to decrease the likelihood of unwanted lithium plating on the inner surface 22 of the conductive housing 20.
  • the conductive housing insulative coating 29 may function to decrease the likelihood of internal short circuiting of the battery 10.
  • the conductive housing insulative coating 29 is a polymer.
  • the conductive housing insulative coating 29 includes one or more of a fluoropolymer such as tetrafluoroethylene, polytetrafluoroethylene, polyvinylidene fluoride, or a combination thereof; a chloropolymer such as polyvinylchloride; another type of polymer such as parylene, poly(ethylene:vinyl acetate), polyether urethane-urea, polyetheretherketone (PEEK), aromatic polyamide, polycarbonate, polyester, polyolefin, polystyrene, polysulfone, polyurethane, polyphenylene sulfide, or a combination thereof.
  • a fluoropolymer such as tetrafluoroethylene, polytetrafluoroethylene, polyvinylidene fluoride, or a combination
  • the polymer is or includes a thermoset resin.
  • a thermoset resin is a polymer that is irreversibly cured by exposure to heat.
  • suitable thermoset resins include, but are not limited to, epoxy resins, polyimide resins, bismaleimide resins, phenol-based resins (e.g., novalac resins), and combinations thereof.
  • the conductive housing insulative coating 29 includes one or more inorganic compounds.
  • suitable inorganic compounds include alumina, tantalum nitride, diamond-like carbon, zirconia, and combinations thereof.
  • 5% or greater, 10% or greater, 20% or greater, 30% or greater, 40% or greater, 50% or greater, 60% or greater, 70% or greater, 80% or greater, 90% or greater, 95% or greater, or 99% or greater of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 99.9% or less, 99% or less, 95% or less, 90% or less, 80% or less, 70% or less, 60% or less, 50% or less, 40% or less, 30% or less, 20% or less, or 10% or less of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 5% to 99.9%, 5% to 99%, 5% to 95%, 5% to 90%, 5% to 80%, 5% to 70%, 5% to 60%, 5% to 50%, 5% to 40%, 5% to 30%, 5% to 20%, or 5% to 10% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 10% to 99.9%, 10% to 99%, 10% to 95%, 10% to 90%, 10% to 80%, 10% to 70%, 10% to 60%, 10% to 50%, 10% to 40%, 10% to 30%, or 10% to 20% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 20% to 99.9%, 20% to 99%, 20% to 95%, 20% to 90%, 20% to 80%, 20% to 70%, 20% to 60%, 20% to 50%, 20% to 40%, or 20% to 30% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 30% to 99.9%, 30% to 99%, 30% to 95%, 30% to 90%, 30% to 80%, 30% to 70%, 30% to 60%, 30% to 50%, or 30% to 40% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 40% to 99.9%, 40% to 99%, 40% to 95%, 40% to 90%, 40% to 80%, 40% to 70%, 40% to 60%, or 40% to 50% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 50% to 99.9%, 50% to 99%, 50% to 95%, 50% to 90%, 50% to 80%, 50% to 70%, or 50% to 60% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 60% to 99.9%, 60% to 99%, 60% to 95%, 60% to 90%, 60% to 80%, or 60% to 70% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 70% to 99.9%, 70% to 99%, 70% to 95%, 70% to 90%, or 70% to 80% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 80% to 99.9%, 80% to 99%, 80% to 95%, or 80% to 90% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • 90% to 99.9%, 90% to 99%, or 90% to 95% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29. In some embodiments, 95% to 99.9% or 95% to 99% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29. In some embodiments, 99% to 99.9% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29.
  • a header assembly 30 is coupled to the proximal end 26 of the conductive housing 20.
  • the header assembly 30 is generally configured to operably couple at least one terminal of the battery 10 to a device that the battery is configured to supply energy to.
  • the header assembly 30 of the illustrative embodiment in FIG. 1 A includes a positive terminal (indicated by the +).
  • a feedthrough pin 80 is exposed to the external environment around the battery 10 through the positive terminal.
  • the feedthrough pin 80 is generally configured to operably couple the positive terminal of battery 10 to the device.
  • the header assembly 30 may include a positive terminal and a negative terminal.
  • the header assembly 30 may include additional components, for example, a plastic and/or glass seal.
  • the header assembly 30 includes a header cap 32.
  • the header cap 32 has a header cap inner surface 36 and a header cap outer surface 34.
  • the outer surface 34 is exposed to the environment outside the battery 10.
  • the inner surface 36 is proximate the electrode assembly 40 and the inner surface 22 of the conductive housing 20.
  • the header cap 32 is generally configured to protect the electrode assembly 40 that is disposed within the conductive housing 20.
  • the header cap 32 may be made of any suitable material such as metal, ceramic, polymer, or combinations thereof.
  • Example metal materials include those described relative to the conductive housing 20.
  • Example polymeric materials include those described elsewhere herein such as relative to the conductive housing 20 and those relative to the conductive housing insulative coating 29.
  • a portion of the header cap 32 is integral with the conductive housing 20. In some embodiments, the header cap 32 is not integral with the conductive housing 20. In embodiments, where the header cap 32 is not integral with the conductive housing 20, any suitable method may be used to couple the header cap 32 to the conductive housing 20 such as welding and soldering.
  • a portion of the header cap inner surface 36 is coated with a header cap insulative coating 38.
  • the header cap insulative coating 38 may be any coating that is non-conductive, that is, has a high resistivity.
  • the header cap insulative coating 38 may be a polymer or an inorganic compound such as those described relative to the conductive housing insulative coating 29.
  • the coatings may be made of the same material.
  • the coatings may be made of different materials.
  • the header cap insulative coating 38 may function to decrease the likelihood of unwanted lithium plating on the inner surface of the header cap 32. As such, in some embodiments, the header cap insulative coating 38 may function to decrease the likelihood of internal short circuiting of the battery 10.
  • a portion of the surface area of the header cap inner surface 36 is coated with the header cap insulative coating 38. In some embodiments 95% or greater, 90% or greater, 80% or greater, 70% or greater, 60% or greater, or 50% or greater of the surface area of the header cap inner surface 36 is coated with the header cap insulative coating 38. In some embodiments no more than 99.9% or less, 90% or less, 80% or less, 70% or less, or 60% or less of the surface area of the header cap inner surface 36 is coated with the header cap insulative coating 38.
  • 50% to 99.9%, 50% to 95%, 50% to 90%, 50% to 80%, 50% to 70%, or 50% to 60% of the surface area of the header cap inner surface 36 is coated with the header cap insulative coating 38.
  • 60% to 99.9%, 60% to 95%, 60% to 90%, 60% to 80%, or 60% to 70% of the surface area of the header cap inner surface 36 is coated with the header cap insulative coating 38.
  • 70% to 99.9%, 70% to 95%, 70% to 90%, or 70% to 80% of the surface area of the header cap inner surface 36 is coated with the header cap insulative coating 38.
  • 80% to 99.9%, 80% to 95%, or 80% to 90% of the surface area of the header cap inner surface 36 is coated with the header cap insulative coating 38. In some embodiments, 90% to 99.9% or 90% to 95% of the surface area of header cap inner surface 36 is coated with the header cap insulative coating 38. In some embodiments, 95% to 99.9% of the surface area of the header cap inner surface 36 is coated with the header cap insulative coating 38.
  • the battery 10 includes an electrode assembly 40.
  • the electrode assembly 40 includes at least two electrodes (e.g., an anode 50 and a cathode 60), an interelectrode region 42, and an electrolyte 70.
  • the electrolyte 70 may be a solid-state electrolyte (discussed elsewhere herein).
  • the electrolyte 70 may be a liquid electrolyte (discussed elsewhere herein).
  • the at least two electrodes include an anode 50 and a cathode 60.
  • the anode 50 is generally configured as a negative electrode at which oxidation reactions take place.
  • the anode 50 generally includes lithium.
  • the lithium may be in the form of metallic lithium, or lithium intercalating materials such as graphite, lithium titanate (Li4TisOi2), or lithium alloys such as lithium-aluminum, lithium-silicon, lithium -bismuth, lithiumcadmium, lithium-magnesium, lithium-tin, lithium-antimony, lithium-germanium, lithium-lead, oxides thereof, sulfides thereof, phosphides thereof, carbides thereof, nitrides thereof, and combinations thereof.
  • the anode 50 includes metallic lithium.
  • the cathode 60 is generally configured as a positive electrode at which reduction reactions take place.
  • cathode materials include, but are not limited to, lithium cobalt oxide (e.g., LiCoCh), lithium iron phosphate (e.g., LiFePCU), lithium magnesium oxide (e.g., LiMmCU), lithium nickel manganese cobalt oxide (e.g., Li(NiMnCo)O2), lithium nickel oxide (e.g., LiNiCh), lithium nickel cobalt aluminum oxide (e.g., Li(NiCoAl)O2), carbon monofluoride, silver vanadium oxide (e.g., Ag2V40n), manganese dioxide (MnCh), and combinations thereof.
  • lithium cobalt oxide e.g., LiCoCh
  • LiFePCU lithium iron phosphate
  • LiMmCU lithium magnesium oxide
  • lithium nickel manganese cobalt oxide e.g., Li(NiMnCo)O2
  • lithium nickel oxide e
  • the cathode may include carbon monofluoride, silver vanadium oxide (e.g., Ag2V40n), or both. In some embodiments where the battery is a primary battery, the cathode may include manganese dioxide (MnCh). The cathode may further include additional components, for example, one or more polymers.
  • the cathode 60 is porous.
  • the degree of the porous structure of the cathode 60 may be quantified as porosity.
  • Porosity is unitless and often given as a percent. Porosity may be calculated using equation 1 :
  • V P porosity — x 100 Vr
  • Vp is the total pore volume and VT is the total volume.
  • Vp is total pore volume of the cathode 60.
  • VT is sum of the total pore volume and the total solid volume of the cathode.
  • the Vp, VT, and thus the porosity of the cathode 60 may be quantified using a variety of methods such as mercury porosimetry; the nitrogen adsorption isotherm method or x-ray, neutron, or other optical imaging methods.
  • the cathode 60 has a porosity that is 5% or greater, 10% or greater, 15% or greater, 20% or greater, 30% or greater, or 40% or greater. In some embodiments, the cathode 60 has a porosity that is 50% or less, 40% or less, 30% or less, 20% or less, 15% or less, or 10% or less. In some embodiments, the cathode 60 has a porosity that is 5% to 50%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, or 5% to 10%. In some embodiments, the cathode 60 has a porosity that is 10% to 50%, 10% to 40%, 10% to 30%, 10% to 20%, or 10% to 15%.
  • the cathode 60 has a porosity that is 15% to 50%, 15% to 40%, 15% to 30%, or 15% to 20%. In some embodiments, the cathode 60 has a porosity that is 20% to 50%, 20% to 40%, or 20% to 30%. In some embodiments, the cathode 60 has a porosity that is 30% to 50% or 30% to 40%. In some embodiments, the cathode 60 has a porosity that is 40% to 50%. In some embodiments, the cathode 60 has a porosity that is 15% to 40%. In some embodiments, the cathode 60 has a porosity that is 15% to 30%.
  • one electrode is physically, and as such, electrically coupled with (e.g., coated on) the conductive case.
  • Physical coupling of at least one electrode to the conductive housing 20 gives the conductive housing 20 a non-neutral polarity.
  • the conductive housing 20 is at a negative polarity.
  • the cathode 60 is physically coupled to at least a portion of the conductive housing 20, the conductive housing 20 is at a positive polarity.
  • a portion of the inner surface 22 of the conductive housing 20 is coated with an electrode (e.g., the anode or the cathode). In some embodiments, as illustrated in FIG. 1 A, a portion of the inner surface of the conductive housing 20 is coated with the anode. Although not shown, it is contemplated that in some embodiments at least a portion of the inner surface of the conductive housing 20 is coated with the cathode.
  • an electrode e.g., the anode or the cathode.
  • 0.1% or greater, 1% or greater, 5% or greater, 10% or greater, 20% or greater, 30% or greater, 40% or greater, 50% or greater, 60% or greater, 70% or greater, 80%, or 90% or greater of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 95% or less, 90% or less, 80% or less, 70% or less, 60% or less, 50% or less, 40%, or less, 30% or less, 20% or less, 10% or less, 5% or less, or 1% or less of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 0.1% to 95%, 0.1% to 90%, 0.1% to 80%, 0.1% to 70%, 0.1% to 60%, 0.1% to 50%, 0.1% to 40%, 0.1% to 30%, 0.1% to 20%, 0.1% to 10%, 0.1% to 5%, or 0.1% to 1% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 1% to 95%, 1% to 90%, 1% to 80%, 1% to 70%, 1% to 60%, 1% to 50%, 1% to 40%, 1% to 30%, 1% to 20%, 1% to 10%, or 1% to 5% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 5% to 95%, 5% to 90%, 5% to 80%, 5% to 70%, 5% to 60%, 5% to 50%, 5% to 40%, 5% to 30%, 5% to 20%, or 5% to 10% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 10% to 95%, 10% to 90%, 10% to 80%, 10% to 70%, 10% to 60%, 10% to 50%, 10% to 40%, 10% to 30%, or 10% to 20% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 20% to 95%, 20% to 90%, 20% to 80%, 20% to 70%, 20% to 60%, 20% to 50%, 20% to 40%, or 20% to 30% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 30% to 95%, 30% to 90%, 30% to 80%, 30% to 70%, 30% to 60%, 30% to 50%, or 30% to 40% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 40% to 95%, 40% to 90%, 40% to 80%, 40% to 70%, 40% to 60%, or 40% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 50% to 95%, 50% to 90%, 50% to 80%, 50% to 70%, or 50% to 60% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 60% to 95%, 60% to 90%, 60% to 80%, or 60% to 80% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 70% to 95%, 70% to 90%, or 70% to 80% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 80% to 95%, or 80% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • 90% to 95% of the surface area of the inner surface 22 of the conductive housing 20 is coated with an electrode.
  • a portion of the inner surface 22 of the conductive housing 20 may be coated with an electrode and at least a portion of the inner surface 22 of the conductive housing 20 not coated with the electrode is coated with a conductive housing insulative coating 29. In some embodiments a greater proportion of the surface area of the inner surface 22 of the conductive housing is coated with an electrode than the conductive housing insulative coating 29. In some embodiments a greater proportion of the surface area of the inner surface 22 of the conductive housing is coated with conductive housing insulative coating 29 than the electrode.
  • the surface area of the electrode relative to the surface area of the conductive housing insulative coating 29 on the inner surface 22 of the conductive housing is one part or greater, five parts or greater, or nine parts or greater for every one part of the conductive housing insulative coating 29. In some embodiments, the surface area of the electrode relative to the surface area of the conductive housing insulative coating 29 on the inner surface 22 of the conductive housing is ten parts or less, nine parts or less, or five parts or less for every one part of the conductive housing insulative coating 29.
  • the surface area of the electrode relative to the surface area of the conductive housing insulative coating 29 on the inner surface 22 of the conductive housing is one part to ten parts, one part to nine parts, or one part to five parts for every one part of the conductive housing insulative coating 29. In some embodiments, the surface area of the electrode relative to the surface area of the conductive housing insulative coating 29 on the inner surface 22 of the conductive housing is five parts to ten parts or five parts to nine parts for every one part of the conductive housing insulative coating 29.
  • the surface area of the electrode relative to the surface area of the conductive housing insulative coating 29 on the inner surface 22 of the conductive housing is nine parts to ten parts for every one part of the conductive housing insulative coating 29. In some embodiments, the surface area of the electrode relative to the surface area of the conductive housing insulative coating 29 on the inner surface 22 of the conductive housing is nine parts to every one part of the conductive housing insulative coating 29.
  • at least a portion of the inner surface 22 of the conductive housing may be coated with a conductive insulative coating 29 and at least a portion of the conductive housing insulative coating 29 is coated with the electrode, that is, the conductive housing insulative coating 29 and the electrode overlap.
  • the electrode coating the conductive housing insulative coating 29 must maintain electrical contact with the conductive housing 20. Electrical contact may be maintained, for example, through a spot weld. In some embodiments, the spot weld may penetrate through the conductive housing insulative coating 29 to establish a physical and electrical connection between the conductive housing 20 and the electrode that is coated on the conductive housing insulative coating 29. For example, in some embodiments, 99.9% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29 and 0.1% of the surface area of the inner surface 22 of the conductive housing 20 is coated with the electrode.
  • 99% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29 and 1% of the surface area of the inner surface 22 of the conductive housing 20 is coated with the electrode. In some embodiments, 95% of the surface area of the inner surface 22 of the conductive housing 20 is coated with a conductive housing insulative coating 29 and 5% of the surface area of the inner surface 22 of the conductive housing 20 is coated with the electrode.
  • the electrode assembly 40 includes an electrolyte 70.
  • the electrolyte is a solid-state electrolyte.
  • a solid-state electrolyte is an electrolyte that does not include free flowing liquid.
  • Solid-state electrolytes include all-solid-state electrolytes and quasi-solid-state electrolytes.
  • the solid-state electrolyte includes an all-solid-state electrolyte. Allsolid-state electrolytes have no liquid. Examples of all-solid-state electrolytes include inorganic solid electrolytes and solid polymer electrolytes.
  • the solid-state electrolyte includes a quasi-solid-state electrolyte.
  • Quasi-solid-state electrolytes include an amount of liquid that is immobilized inside a solid matrix. Quasi-solid-state electrolytes include gel polymer electrolytes, plastic crystal electrolytes, ionogel electrolytes, and gel electrolytes. In some embodiments, the solid-state electrolyte includes a gel polymer electrolyte, a plastic crystal electrolyte, an inorganic electrolyte, or a combination thereof.
  • the solid-state electrolyte is a gel polymer electrolyte.
  • a gel polymer electrolyte includes a polymer network that immobilizes a liquid electrolyte containing a solvent and lithium salt.
  • the polymer network may include one or more polymers.
  • lithium salts that may be included in a gel polymer electrolyte include, but are not limited to, lithium triflate, lithium bis(oxalato) borate, lithium hexafluorophosphate, lithium hexafluoroarsenate, lithium trifluoromethanesulfonate, lithium oxalyldifluoroborate, lithium tetrafluoroborate, lithium bisfluorosulfonimide, lithium bistrifluoromethylsulfonimide, lithium difluorophosphate, lithium 4,5-dicyano-2- trifluoromethylimidazolium, lithium difluoro(oxalato)borate, lithium perchlorate, lithium tris(trifluoromethanesulphonyl) methide, and combinations thereof.
  • Example polymers that may be included in a gel polymer electrolyte include, but are not limited to, poly(ethylene oxide) and copolymers such as polyethylenepropylene oxide); polymers based on the acrylic group such as poly(methyl methacrylate), poly(acrylic acid), lithium poly(acrylate), poly(ethylene glycol diacrylate), and combinations thereof; polymers based on the vinylidene fluoride group such as poly(vinylidene fluoride) (PVdF), copolymers such as poly (vinylidene fluoride - hexafluor opr opylene) (PVdF-HFP), and combinations thereof; and combinations thereof.
  • PVdF poly(vinylidene fluoride)
  • PVdF-HFP poly (vinylidene fluoride -HFP)
  • Example solvents that may be included in a gel polymer electrolyte include, but are not limited to, ethylene carbonate, propylene carbonate, diethyl carbonate, dimethyl carbonate, polyethylene glycol), dimethyl sulfoxide, glymes such as monoglyme, diglyme, triglyme and tetraglyme, other aprotic solvents, and combinations thereof. Any suitable combination of one or more lithium salts, one or more polymers, and one or more solvents may be used in a gel polymer electrolyte.
  • the gel polymer electrolyte includes LiAsFe, propylene carbonate/l,2-dimethoxy ethane, and polyethylene oxide (PEO). In some embodiments, the gel polymer electrolyte includes 1 M LiAsFe in 50:50 (vol.%) propylene carbonate/l,2-dimethoxy ethane gelled with polyethylene oxide (PEO); the weight % of PEO in the gel polymer electrolyte being between 5-20%. [050] In some embodiments, the gel polymer electrolyte includes LiBF4 (lithium tetrafluoroborate), gamma-butyrolactone/l,2-dimethoxy ethane, and polyethylene oxide (PEO).
  • LiBF4 lithium tetrafluoroborate
  • gamma-butyrolactone/l,2-dimethoxy ethane and polyethylene oxide (PEO).
  • the gel polymer electrolyte includes 1 M LiBF4 (lithium tetrafluoroborate) in 60:40 (vol.%) gamma-butyrolactone/1,2- dimethoxy ethane gelled with polyethylene oxide (PEO); the weight % of PEO in the gel polymer electrolyte being between 5-20%.
  • LiBF4 lithium tetrafluoroborate
  • PEO polyethylene oxide
  • the gel polymer electrolyte includes LiTFSI (lithium bis(trifluoromethanesulfonyl)imide), tetraglyme, and polyethylene oxide (PEO).
  • the gel polymer electrolyte includes 50 mole-% LiTFSI in tetraglyme gelled with polyethylene oxide; the weight % PEO in the gelled electrolyte being between 5-50%
  • the gel polymer electrolyte is a gel polymer electrolyte as described in US patent No. 9,911,984 to Tamirisa et al.; US patent No. 10,333,173 to Ye et al.; US patent No. 10,587,005 to Li et al.; or US patent No. 10,727,499 to Tamirisa et al., each of which are incorporated here by reference.
  • the solid-state electrolyte is a plastic crystal electrolyte.
  • a plastic crystal is crystal where the molecules making up the crystal weakly interact to impose degree of long-range translational order while maintaining a degree of orientational or confirmational freedom.
  • a plastic crystal electrolyte generally includes one or more lithium salts and a plastic crystal forming material capable of dissolving the one or more lithium salts.
  • Lithium salts suitable for use in a plastic crystal electrolyte include, but are not limited to, trifluoromethanesulphonylimide, lithium bis-perfluoroethylsulphonylimide, lithium tetrafluoroborate, lithium hexafluorophosphate, lithium thiocyanate, lithium triflate, lithium tetrafluoroaluminate, lithium perchlorate, and combinations thereof.
  • the plastic crystal electrolyte may be a nonionic plastic crystal electrolyte, an ionic plastic crystal electrolyte, or a combination thereof.
  • Nonionic plastic crystal electrolytes are made from neutral plastic crystal forming materials. Examples of nonionic plastic crystal forming materials include succinonitrile.
  • Ionic plastic crystals are made from a charged plastic crystal forming material. Examples of ionic plastic crystal forming materials include, but are not limited to, phosphonium materials such as tri ethylmethyl ammonium bis(fluorosu1fonyl)imide and triisobutylmethylphosphonium bis(fluorosulfonyl)imide.
  • the solid-state electrolyte is an inorganic electrolyte.
  • Inorganic electrolytes include one or more inorganic materials that are in a crystalline state.
  • the inorganic electrolytes generally include lithium.
  • inorganic electrolytes include, but are not limited to, argyrodite type electrolytes such as LiePSsX where X is Cl, Br, or I; perovskite type electrolytes such as Lio.35,Lao.55Ti03; anti-perovskite type electrolyte such as LisOClo.sBro.s; sodium superionic conductor (NASICON) electrolyte types such as lithium aluminum titanium phosphate (LATP; e.g., Lii.2Alo.2Tii.8(P04)3), lithium aluminum germanium phosphate, lithium titanium phosphorous, and combinations thereof; lithium super ionic conductor (LISICON) type electrolyte such as lithium germanium phosphorous sulfide, lithium silico phosphorous sulfur, lithium phosphorous sulfur, Li2+2xZm- x GeO4, and combinations thereof; thi-LISICON type electrolyte such as LiioGeP2Si2; Garnet type
  • the electrolyte 70 is a liquid electrolyte.
  • liquid electrolyte refers to an electrolyte that is free flowing.
  • the liquid electrolytes of the present disclosure generally include a solvent and ions dissolved within the solvent. Any salt or combinations of salts discussed relative to the gel polymer electrolyte may be included in a liquid electrolyte. Any solvent or combinations of solvents discussed relative to the gel polymer electrolyte may be included in the liquid electrolyte.
  • An interelectrode region 42 exists between the anode 50 and the cathode 60.
  • the interelectrode region 42 includes an interelectrode volume (Vi).
  • the interelectrode volume is the total volume in the electrode assembly 40 that is physically available to be occupied, but not necessarily occupied, by the electrolyte.
  • the interelectrode volume is the total volume in the electrode assembly 40 that is physically available to be occupied, but not necessarily occupied, by a solid-state electrolyte.
  • the interelectrode volume includes the pores of the separator and excludes the nonporous volume of the separator.
  • the interelectrode region 42 includes a porous separator 90.
  • the porous separator 90 is generally configured to inhibit direct interaction between the cathode 60 and the anode 50, thus limiting the likelihood of internal short circuits.
  • the porous separator 90 is also generally configured to allow the transport of ions between the cathode 60 and anode 50.
  • the porous separator 90 is not in direct physical contact with an electrode.
  • the porous separator 90 may be in direct contact with one or more of the electrodes.
  • the porous separator 90 is generally porous. At least some of the pores of the porous separator 90 are permeable, that is, they allow the ions to flow from one side of the porous separator 90 to the other side of the porous separator 90. In some embodiments, all or substantially all of the pores of the porous separator 90 are permeable. In some embodiments, a portion of the pores of the porous separator 90 are permeable and a portion of the pores are not permeable. Similar to the cathode 60, the extent of pores in the porous separator 90 may be given by the porosity described by equation 1 above.
  • Vv is the total volume of the pores in the separator and VT is the sum of total volume of the pores and the total volume of the solid of the porous separator 90.
  • the Vv, VT, and thus the porosity of a separator may be calculated using a variety of methods such as those described relative to the cathode 60.
  • the porosity of the porous separator 90 is 20% or greater, 30% or greater, 40% or greater, 50% or greater, 60% or greater, or 70% or greater. In some embodiments, the porosity of the porous separator 90 is 80% or less, 70% or less, 60% or less, 50% or less, 40% or less, 30% or less, or 20% or less. In some embodiments, the porosity of the porous separator 90 is 20% to 80%, 20% to 70%, 20% to 60%, 20% to 50%, 20% to 40%, or 20% to 30%. In some embodiments, the porosity of the porous separator 90 is 30% to 80%, 30% to 70%, 30% to 60%, 30% to 50%, or 30% to 40%.
  • the porosity of the porous separator 90 is 40% to 80%, 40% to 70%, 40% to 60%, or 40% to 50%. In some embodiments, the porosity of the porous separator 90 is 50% to 80%, 50% to 70%, or 50% to 60%. In some embodiments, the porosity of the porous separator 90 is 60% to 80% or 60% to 70%. In some embodiments, the porosity of the porous separator 90 is 70% to 80%. In some embodiments, the porosity of the separator is 40%-60%.
  • Example separators include, but are not limited to, polymeric porous membranes such as polyethylene, polypropylene, polyterephthalate, polyimide, cellulose based polymers and combinations thereof; modified polymeric membranes with thin oxide coatings of titania (TiCh), zinc oxide (ZnO), silica (SiCh), and combinations thereof; and hybrid organic-organic assemblies such as those that contain SiCh nanoparticles covalently tethered within a polymeric network such as polyurethanes, polyacrylates, polyethylene glycol, and combinations thereof; and combinations thereof. In some embodiments, more than one separator may be used.
  • polymeric porous membranes such as polyethylene, polypropylene, polyterephthalate, polyimide, cellulose based polymers and combinations thereof
  • hybrid organic-organic assemblies such as those that contain SiCh nanoparticles covalently
  • the electrolyte 70 is confined to a void volume (Vv).
  • a solid state electrolyte is confined to a void volume (Vv).
  • the Vv is defined by equation 2:
  • V v V P + Vj
  • Vp is the total cathode pore volume
  • Vi is the interelectrode volume.
  • the Vi is includes the total pore volume of the separator.
  • the electrolyte 70 may occupy a portion of the void volume (Vv). In some embodiments, the solid-state electrolyte may occupy a portion of the void volume (Vv). In some embodiments the solid-state electrolyte occupies 50% or greater, 60% or greater, 70% or greater, 80% or greater, 90% or greater, 95%, or greater than 97% of the Vv. In some embodiments, the solid-state electrolyte occupies 99.9% or less, 97% or less, 95% or less, 90% or less, 80% or less, 70% or less, or 60% or less of the Vv.
  • the solid-state electrolyte occupies 50% to 99.9%, 50% to 97%, 50% to 95%, 50% to 90%, 50% to 80% 50% to 70% or 50% to 60% of the Vv. In some embodiments, the solid-state electrolyte occupies 60% to 99.9%, 60% to 97%, 60% to 95%, 60% to 90%, 60% to 80%, or 60% to 70% of the Vv. In some embodiments, the solid-state electrolyte occupies 70% to 99.9%, 70% to 97%, 70% to 95%, 70% to 90%, or 70% to 80% of the Vv. In some embodiments, the solid-state electrolyte occupies 80% to 99.9%, 80% to 97%, 80% to 95%, or 80% to 90% of the Vv.
  • the solid-state electrolyte occupies 90% to 99.9%, 90% to 97%, or 90% to 95% of the Vv. In some embodiments, the solid-state electrolyte occupies 95% to 99.9% or 95% to 97% of the Vv. In some embodiments, the solid-state electrolyte occupies 97% to 99.9% of the Vv. In some embodiments, the solid-state electrolyte occupies 90% or greater of the Vv.
  • the methods used to deposit the solid-state electrolyte within the electrode assembly 40 in may increase the likelihood of the solid-state electrolyte being confined to the Vv.
  • Such methods include, but are not limited to, in situ polymerization and/or melt infiltration of the solid-state electrolyte into the Vv.
  • In situ polymerization refers to polymerizing an electrolyte precursor mixture within the electrode assembly 40 to form the solid-state electrolyte (described in detail below).
  • in situ polymerization may be used to deposit a gel polymer electrolyte within the electrode assembly 40.
  • the solid-state electrolyte includes or is an in situ polymerized gel.
  • Melt infiltration refers to depositing a liquid electrolyte precursor into the electrode assembly 40 followed by freezing the liquid electrolyte precursor to from the solid-state electrolyte.
  • melt infiltration is used to deposit an inorganic electrolyte or a plastic crystal electrolyte in the electrode assembly 40.
  • the solid-state electrolyte includes or is a melt-infiltrated inorganic electrolyte.
  • the solid-state electrolyte includes or is a melt-infiltrated plastic crystal electrolyte. In both methods, the volume of the solid-state electrolyte is adjusted so as not to exceed the Vv.
  • FIG. 2 illustrates the general steps used in some embodiments to deposit the solid-state 70 electrolyte into the electrode assembly 40.
  • depositing the solid-state electrolyte into the electrode assembly includes mixing an electrolyte pre-cursor to form a solid-state precursor mixture 100.
  • the method further includes adding a volume of the solid-state precursor mixture to the electrode assembly 200.
  • the method further includes forming the solid-state electrolyte 300.
  • the electrolyte precursor includes any compound or compounds useful for forming a solid-state electrolyte such as those solid-state electrolytes discussed elsewhere (e.g., a gel polymer electrolyte, polymer electrolyte, a plastic crystal electrolyte, or an inorganic electrolyte).
  • the electrolyte precursor includes one or more lithium salt species and one or more monomer species suitable for forming a gel polymer electrolyte.
  • the gel polymer solid-state electrolyte includes or is an in situ polymerized gel electrolyte.
  • the electrolyte precursor may include one or more initiator species suitable for initiating the polymerization of one or more monomer species to form a solid-state electrolyte (e.g., gel polymer electrolyte).
  • the electrolyte may include one or more solvents suitable for the formation of a solid-state electrolyte.
  • the electrolyte precursor may include one or more lithium salt species and one or more compound species suitable for forming a plastic crystal electrolyte.
  • the electrolyte precursor may include one or more lithium salts suitable for forming an inorganic electrolyte.
  • the solid-state electrolyte 70 includes or is a melt-infiltrated inorganic electrolyte. In some embodiments, the solid-state electrolyte 70 includes or is a melt-infiltrated plastic crystal electrolyte.
  • mixing an electrolyte pre-cursor to form a solid- state precursor mixture 100 is done at temperature above the melting temperature of the electrolyte pre-cursor components, for example, when employing the melt infiltration deposition technique.
  • adding a volume of the solid-state precursor mixture to the electrode assembly 200 includes adding a volume equal to or less than the Vv.
  • the Vv may be calculated as described above in equation 2.
  • adding a volume of the solid-state precursor mixture to the electrode assembly 200 is done at a temperature above the melting temperature of the electrolyte pre-cursor components, for example, when employing the melt infiltration deposition technique.
  • forming the solid-state electrolyte 300 includes polymerizing the solid-state precursor mixture, for example, when employing the in-situ polymerization deposition technique.
  • the solid-state precursor mixture is exposed to a thermal treatment thereby forming the solid-state electrolyte.
  • the solid-state precursor mixture is exposed to a thermal treatment thereby forming the gel polymer electrolyte.
  • the solid-state precursor mixture is exposed to an ultraviolet treatment thereby forming the solid-state electrolyte.
  • the solid-state precursor mixture is exposed to an ultraviolet treatment thereby forming the gel polymer electrolyte.
  • forming the solid-state electrolyte 300 includes freezing the solid-state precursor mixture, for example, when employing the melt infiltration deposition technique. This method includes cooling the solid-state precursor mixture to a temperature that is below the freezing point of the components of the solid-state precursor mixture to form the solid-state electrolyte 300. In some embodiments, this method includes cooling the solid-state precursor mixture to a temperature that is below the freezing point of the components of the solid-state precursor mixture to form an inorganic electrolyte. In some embodiments, this method includes cooling the solid-state precursor mixture to a temperature that is below the freezing point of the components of the solid-state precursor mixture to form a plastic crystal electrolyte.
  • Electrode insulating, non-porous coatings that do not intercalate or react with lithium ions can be achieved through various physical vapor deposition (PVD), chemical vapor deposition (CVD) or atomic layer deposition (ALD) methods.
  • PVD physical vapor deposition
  • CVD chemical vapor deposition
  • ALD atomic layer deposition
  • AI2O3 coatings may be deposited by RF sputtering, cathodic arc deposition, electron beam evaporation.
  • the regions 29 and 38 inside the battery may be exposed to the coating during the thin film deposition process by masking the rest of the inside surface of the battery (22) either through physical, shadow masks or photoresist based lithographical masks.
  • Coating thicknesses may range between 200 nanometers and 5 micrometers with the intent to achieve a dense, non-porous film that shields the underlying surface from contact with the battery electrolyte.
  • multi-layer films may be deposited with varying porosities to achieve robust films with good adhesion to the underlying substrate (inner surface of the battery, 22) and mechanical integrity to withstand the use conditions of the films inside the battery, e.g., high temperature and low temperature exposures that may cause stresses to build inside the films that can potentially lead to delamination or cracking.
  • the multi-layer films may also include adhesion promoting layers immediately adjacent to the inner surface of the battery, 22, different in chemical composition from the top layer film exposed to the battery electrolyte.
  • Liquid electrolyte containing 20 mol% LiTFSI dissolved in tetraglyme was mixed with polyethylene glycol diacrylate (PEGDA 750 Da) such that the resulting solution contained 10 wt.% PEGDA in the combined electrolyte.
  • Thermal initiator, benzoyl peroxide (Luperox A98), measuring 1% of the total weight of PEGDA was introduced into the combined electrolyte to create the pre-gelled electrolyte precursor.
  • Crosslinked, gelled electrolyte was achieved by exposing the pre-gelled electrolyte precursor to 75 °C for approximately 100 minutes.
  • the pre-gelled electrolyte precursor is filled into the battery to fill the pores of the electrode and separator assembly first. Subsequently, the battery containing the electrode assembly and the pre-gelled electrolyte precursor is exposed to elevated temperature, such as 75 °C for up to 100 minutes to gel the electrolyte in place, in the pores of the electrode, separator assembly.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • General Physics & Mathematics (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Sealing Battery Cases Or Jackets (AREA)

Abstract

L'invention concerne une batterie comprenant un boîtier conducteur, un ensemble collecteur et un ensemble électrode, l'ensemble électrode comprenant un électrolyte à l'état solide. L'invention concerne en outre une batterie comprenant un boîtier conducteur ayant une surface interne et une surface externe, un ensemble collecteur, un ensemble électrode et un revêtement électriquement isolant sur au moins une partie de la surface interne du boîtier conducteur.
PCT/IB2023/051912 2022-03-30 2023-03-01 Batteries et leurs procédés de fabrication WO2023187498A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202263325334P 2022-03-30 2022-03-30
US63/325,334 2022-03-30
US18/114,027 US20230318097A1 (en) 2022-03-30 2023-02-24 Batteries and methods of making the same
US18/114,027 2023-02-24

Publications (1)

Publication Number Publication Date
WO2023187498A1 true WO2023187498A1 (fr) 2023-10-05

Family

ID=85685310

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2023/051912 WO2023187498A1 (fr) 2022-03-30 2023-03-01 Batteries et leurs procédés de fabrication

Country Status (1)

Country Link
WO (1) WO2023187498A1 (fr)

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1914818B1 (fr) * 2006-10-06 2013-07-24 Greatbatch Ltd. Cellule électrochimique très compacte
US20140170470A1 (en) * 2012-05-29 2014-06-19 Lg Chem, Ltd. Secondary battery and method for manufacturing the same
WO2015151144A1 (fr) * 2014-03-31 2015-10-08 株式会社日立製作所 Batterie rechargeable au lithium tout solide
US20180019458A1 (en) * 2013-12-19 2018-01-18 Sony Corporation Electrode, secondary battery, battery pack, electric vehicle, electric power storage system, electric power tool, and electronic apparatus
US9911984B2 (en) 2014-06-17 2018-03-06 Medtronic, Inc. Semi-solid electrolytes for batteries
CN109616695A (zh) * 2018-10-19 2019-04-12 安徽正熹标王新能源有限公司 一种锂离子电池及锂离子电池的制造方法
US10333173B2 (en) 2014-11-14 2019-06-25 Medtronic, Inc. Composite separator and electrolyte for solid state batteries
US10587005B2 (en) 2016-03-30 2020-03-10 Wildcat Discovery Technologies, Inc. Solid electrolyte compositions

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1914818B1 (fr) * 2006-10-06 2013-07-24 Greatbatch Ltd. Cellule électrochimique très compacte
US20140170470A1 (en) * 2012-05-29 2014-06-19 Lg Chem, Ltd. Secondary battery and method for manufacturing the same
US20180019458A1 (en) * 2013-12-19 2018-01-18 Sony Corporation Electrode, secondary battery, battery pack, electric vehicle, electric power storage system, electric power tool, and electronic apparatus
WO2015151144A1 (fr) * 2014-03-31 2015-10-08 株式会社日立製作所 Batterie rechargeable au lithium tout solide
US9911984B2 (en) 2014-06-17 2018-03-06 Medtronic, Inc. Semi-solid electrolytes for batteries
US10727499B2 (en) 2014-06-17 2020-07-28 Medtronic, Inc. Semi-solid electrolytes for batteries
US10333173B2 (en) 2014-11-14 2019-06-25 Medtronic, Inc. Composite separator and electrolyte for solid state batteries
US10587005B2 (en) 2016-03-30 2020-03-10 Wildcat Discovery Technologies, Inc. Solid electrolyte compositions
CN109616695A (zh) * 2018-10-19 2019-04-12 安徽正熹标王新能源有限公司 一种锂离子电池及锂离子电池的制造方法

Similar Documents

Publication Publication Date Title
CN109526240B (zh) 可再充电电池
US11646472B2 (en) Making lithium metal—seawater battery cells having protected lithium electrodes
Li et al. Suppression of dendritic lithium growth in lithium metal-based batteries
US10847805B2 (en) Current collector clad with lithium ion conducting solid electrolyte
US8334075B2 (en) Substantially impervious lithium super ion conducting membranes
JP3787564B2 (ja) リチウム電池用リチウムメタル・アノード
CN110809830B (zh) 用于电子元件和电池的封装系统
US10461360B2 (en) Electrode compositions for solid-state batteries
US20070012244A1 (en) Apparatus and method for making thin-film batteries with soft and hard electrolyte layers
CA2615479A1 (fr) Piles a couches minces avec couches electrolytes de polymere et de lipon et methodes
US20200052304A1 (en) Energy storage, bipolar electrode arrangement and method
KR20190065577A (ko) 리튬 전극, 이의 제조방법 및 이를 포함하는 리튬 이차전지
US20210359338A1 (en) Solid state battery, ceramic electrolyte structure and methods of making
US10483586B2 (en) All-solid-state battery using sodium ion intercalation cathode with Li/Na exchanging layer
US20200106068A1 (en) Composite separator for lithium metal batteries
US20230318097A1 (en) Batteries and methods of making the same
WO2023187498A1 (fr) Batteries et leurs procédés de fabrication
WO2023277858A1 (fr) Piles/batteries comprenant des membranes conductrices ioniques à l'état solide
US11881553B1 (en) Dendrite suppressing solid electrolyte structures and related methods and systems
US20240021837A1 (en) Coated three-dimensional electronically conductive network
WO2024115994A1 (fr) Collecteur de courant de batterie résistant à la corrosion
Silva et al. Solid-state thin-films lithium batteries for integration in microsystems JF Ribeiro, MF Silva, JP Carmo, LM Gonçalves
Huang et al. Lithium metal anode: Past, present, and future

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 23711560

Country of ref document: EP

Kind code of ref document: A1