Current collector clad with lithium ion conducting solid electrolyte

Patent metadata

Field	Value
Publication number	US-10847805-B2
Application number	US-201916243525-A
Country	US
Kind code	B2
Filing date	Jan 9, 2019
Priority date	Jan 9, 2018
Publication date	Nov 24, 2020
Grant date	Nov 24, 2020

Abstract

An article for forming an electrochemical device is disclosed. The article comprises a metallic current collector clad with an ion conducting solid-electrolyte material such that intimate contact between the current collector and the ion conducting solid-electrolyte material is made. A lithium metal anode can be formed in situ between the current collector clad and the ion conducting solid-electrolyte material from lithium ions contained within a cathode material that is placed in contact with the ion conducting solid-electrolyte material. A bipolar electrochemical cell can be constructed from the article.

First claim

What is claimed is:

1. An article for forming an electrochemical device, the article comprising:
a plurality of layered structures, each layered structure comprising:
(i) a current collector clad with a solid-state electrolyte material, and
(ii) a cathode active material in contact with the solid-state electrolyte material,

wherein a current collector of one of the layered structures is in contact with cathode active material of another of the layered structures.

2. The article of claim 1 , wherein each layered structure is unformed.

3. The article of claim 1 , wherein the current collector comprises a single material comprising a metal or a metal alloy.

4. The article of claim 3 , wherein the current collector comprises a material selected from the group consisting of nickel, molybdenum, titanium, zirconium, tantalum, alloy steel, stainless steel, nickel based super alloys, cobalt based super alloys, copper, aluminum, or mixtures thereof.

5. The article of claim 1 , wherein the current collector comprises a bimetal having a first material that at least partially contacts the solid-state electrolyte material and a second material that at least partially contacts the cathode active material of another of the layered structures.

6. The article of claim 5 , wherein the first material is selected from the group consisting of nickel, molybdenum, titanium, zirconium, tantalum, alloy steel, stainless steel, nickel based super alloys, cobalt based super alloys, copper, or mixtures thereof.

7. The article of claim 5 , wherein the second material is selected from the group consisting of aluminum, nickel, alloy steel, stainless steel, nickel based super alloys, or mixtures thereof.

8. The article of claim 1 , wherein the current collector has a thickness between 1 nanometer and 100 micrometers.

9. The article of claim 1 , wherein the solid-state electrolyte material comprises a material selected from the group consisting of lithium phosphorous oxynitride (LiPON), oxide based garnets, sodium super ionic conductors (NaSICON), lithium super ionic conductors (LiSICON), thio-LiSICONs, sulfide glass, polymers, or mixtures thereof.

10. The article of claim 9 , wherein the solid-state electrolyte material is selected from the group consisting of lithium lanthanum zirconium oxide (LLZO), aluminum doped LLZO, tantalum doped LLZO, lithium aluminum titanium phosphate (LATP), lithium aluminum germanium phosphate (LAGP), lithium phosphorous sulfide (LPS), poly(ethylene oxide) (PEO), polyacrylonitrile (PAN), crystalline thermoplastic polymers, or mixtures thereof.

11. The article of claim 10 , wherein the solid-state electrolyte material comprises lithium lanthanum zirconium oxide (LLZO) or a derivative thereof.

12. The article of claim 1 , wherein the solid-state electrolyte material has a thickness between 1 nanometer and 100 micrometers.

13. The article of claim 1 , wherein the cathode active material comprises an active material selected from the group consisting of layered oxides, olivine phosphates, spinel oxides, disordered rock salt oxides, conversion cathodes, sulfur, lithium titanium sulfide, vanadium oxide, or mixtures thereof.

14. The article of claim 13 , wherein the active material comprises at least one of lithium cobalt oxide (LCO), lithium nickel manganese cobalt oxide, lithium nickel oxide (LNO), lithium nickel cobalt aluminum oxide (NCA), lithium iron phosphate (LFP), lithium nickel phosphate (LNP), lithium cobalt phosphate (LCP), lithium manganese phosphate (LMP), lithium manganese oxide (LMO), lithium nickel manganese oxide (LMNO), lithium nickel zirconium oxide, lithium zirconium oxide, lithium magnesium zirconium oxide, lithium nickel tantalum oxide, lithium niobium oxide, lithium iron sulfide, lithium copper fluoride, lithium iron fluoride, or mixtures thereof.

15. The article of claim 1 , wherein the cathode active material forms a composite cathode layer along with an ion conducting material.

16. The article of claim 15 , wherein the ion conducting material comprises at least one of an oxide solid electrolyte, a phosphate solid electrolyte, a sulfur based solid electrolyte, a polymer based solid electrolyte, or a gel based electrolyte.

17. The article of claim 1 , wherein the cathode active material has a thickness between 1 nanometer and 400 micrometers.

18. A method of making an electrochemical device, the method comprising:
(a) providing a layer of a cathode active material;
(b) providing a current collector clad with a solid-state electrolyte material;
(c) placing the layer of the cathode active material in contact with the solid-state electrolyte material to create a first layered structure;
(d) repeating steps (a) to (c) to create a second layered structure; and
(e) combining the first layered structure and the second layered structure such that a current collector of the first layered structure is in contact with cathode active material of the second layered structure.

19. The method of claim 18 , wherein step (d) is repeated several times to create a plurality of layered structures to be combined using the procedure of step (e).

20. The method of claim 18 , wherein the current collector comprises a material selected from the group consisting of nickel, molybdenum, titanium, zirconium, tantalum, alloy steel, stainless steel, nickel based super alloys, cobalt based super alloys, copper, aluminum, or mixtures thereof.

21. The method of claim 18 , wherein the current collector comprises a bimetal having a first material that at least partially contacts the solid-state electrolyte material and a second material that at least partially contacts the cathode active material of the adjacent layered structure,
wherein the first material is selected from the group consisting of nickel, molybdenum, titanium, zirconium, tantalum, alloy steel, stainless steel, nickel based super alloys, cobalt based super alloys, copper, or mixtures thereof, and
wherein the second material is selected from the group consisting of aluminum, nickel, alloy steel, stainless steel, nickel based super alloys, or mixtures thereof.

22. The method of claim 18 , wherein the current collector has a thickness between 1 nanometer and 100 micrometers.

23. The method of claim 18 , wherein the solid-state electrolyte material comprises a material selected from the group consisting of lithium phosphorous oxynitride (LiPON), oxide based garnets, sodium super ionic conductors (NaSICON), lithium super ionic conductors (LiSICON), thio-LiSICONs, sulfide glass, polymers, or mixtures thereof.

24. The method of claim 18 , wherein the solid-state electrolyte material is comprised of a material selected from the group consisting of lithium lanthanum zirconium oxide (LLZO), aluminum doped LLZO, tantalum doped LLZO, lithium aluminum titanium phosphate (LATP), lithium aluminum germanium phosphate (LAGP), lithium phosphorous sulfide (LPS), poly(ethylene oxide) (PEO), polyacrylonitrile (PAN), crystalline thermoplastic polymers, or mixtures thereof.

25. The method of claim 18 , wherein the solid-state electrolyte material comprises lithium lanthanum zirconium oxide (LLZO) or a derivative thereof.

26. The method of claim 18 , wherein the solid-state electrolyte material is clad onto the current collector using at least one of chemical vapor deposition, physical vapor deposition, atomic layer deposition, slurry casting and sintering, painting, powder c

Assignees

• Univ Michigan Regents

Inventors

• Sakamoto Jeffrey
• Thompson Travis
• Taylor Nathan

Classifications

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• H01M2300/0077

  based on zirconium oxide · CPC title

• H01M4/582

  Halogenides · CPC title

• H01M4/661

  Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence) · CPC title

• H01M4/485 Primary

  of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy (H01M4/505, H01M4/525 take precedence) · CPC title