Energy device with lithium

Patent metadata

Field	Value
Publication number	US-11271201-B2
Application number	US-201916521020-A
Country	US
Kind code	B2
Filing date	Jul 24, 2019
Priority date	Jul 15, 2019
Publication date	Mar 8, 2022
Grant date	Mar 8, 2022

Abstract

An energy device has an electrode including lithium cobaltite (LCO) grains, where the LCO grains are sintered to one another forming a self-supporting sheet with porous passages. The porous passages wind and branch through the sheet. The energy device further includes a solid electrolyte comprising lithium phosphosulfide (LPS) overlaying a major surface of the sheet and extending into the porous passages. The sheet serves as mechanical support for the solid electrolyte, allowing for high temperature joining of the LPS to the LCO without binder in the LPS.

First claim

What is claimed is:

1. An energy device, comprising:
an electrode comprising a ceramic sheet, wherein the ceramic comprises lithium, wherein the sheet is porous, wherein porosity of the sheet is such that pores open to surfaces of the sheet and pores open to one another and are connected to one another within the sheet forming passages that wind and branch through the sheet; and
a solid electrolyte comprising lithium overlaying a first major surface of the porous sheet of the electrode and extending into the passages of the sheet,
the solid electrolyte is also overlaying a second major surface of the sheet of the electrode, and wherein the solid electrolyte extends through the passages and connects together the solid electrolyte overlaying the first and second surfaces.

2. The energy device of claim 1 , wherein the ceramic of the sheet of the electrode comprises lithium cobaltite (LCO).

3. The energy device of claim 2 , wherein the solid electrolyte overlaying the first major surface of the sheet of the electrode has a density of at least 90%.

4. The energy device of claim 2 , further comprising a current collector, wherein the current collector overlays, directly contacts, and electrically connects to the solid electrolyte.

5. The energy device of claim 2 , wherein the sheet of the electrode mechanically supports the solid electrolyte and correspondingly geometrically constrains the solid electrolyte such that, in terms of area, a footprint of the solid electrolyte facing the sheet of the electrode is not greater than 120% of a footprint of the first major surface of the sheet of the electrode.

6. The energy device of claim 2 , wherein at least some of the passages have a length of at least 10 μm, and wherein the solid electrolyte extends into at least some of the passages a distance of at least 3 μm inward from the first major surface.

7. The energy device of claim 6 , wherein the sheet of the electrode has a thickness greater than 10 μm and less than 100 μm, and the solid electrolyte extends outward from the first major surface by less than 100 μm, thereby facilitating a particularly thin device.

8. An energy device, comprising:
an electrode comprising lithium cobaltite (LCO) forming a porous sheet with passages, wherein the passages wind and branch through the sheet; and
a solid electrolyte comprising lithium encapsulating the electrode such that the solid electrolyte overlays both a first major surface and a second major surface of the sheet of LCO and extends into the passages,
wherein at least some of the passages have a length of at least 10 μm, and wherein the solid electrolyte extends into at least some of the passages a distance of at least 3 μm inward from the first and second major surfaces.

9. The energy device of claim 8 , wherein the solid electrolyte overlaying the first and second major of the sheet surfaces has a density of at least 90%, and wherein at least 90% by volume of the solid electrolyte consists of inorganic crystalline or amorphous glassy solid electrolyte, as opposed to organic binder.

10. The energy device of claim 8 , further comprising a current collector, wherein the current collector overlays, directly contacts, and electrically connects to the solid electrolyte.

11. The energy device of claim 8 , wherein the sheet of LCO mechanically supports the solid electrolyte and correspondingly geometrically constrains the solid electrolyte such that, in terms of area, a footprint of the solid electrolyte facing the first major surface of the sheet of LCO is not greater than 120% of a footprint of the first major surface.

12. The energy device of claim 8 , wherein the solid electrolyte extends through the passages and connects together the solid electrolyte overlaying the first and second surfaces, thereby facilitating efficiency through enhanced interfacing of the electrode to solid electrolyte.

13. The energy device of claim 8 , wherein the sheet of LCO has a thickness greater than 10 μm and less than 100 μm, and the solid electrolyte extends outward from each of the first and second major surfaces by less than 100 μm.

14. An energy device, comprising:
a cathode comprising lithium cobaltite (LCO) forming a porous sheet with passages, wherein the passages wind and branch through the sheet; and
a solid electrolyte comprising lithium overlaying both a first major surface and a second major surface of the sheet of LCO and extending into the passages,
a current collector, wherein the device is anode-less such that the current collector overlays, directly contacts, and electrically connects to the solid electrolyte.

15. The energy device of claim 14 , wherein the sheet of LCO mechanically supports the solid electrolyte and correspondingly geometrically constrains the solid electrolyte such that, in terms of area, a footprint of the solid electrolyte facing the sheet of LCO is not greater than 120% of a footprint of the first major surface of the sheet of LCO.

16. The energy device of claim 14 , wherein at least some of the passages have a length of at least 10 μm, and wherein the solid electrolyte extends into at least some of the passages a distance of at least 3 μm inward from the first major surface.

17. The energy device of claim 14 , wherein the sheet of LCO has a thickness greater than 10 μm and less than 100 μm, and the solid electrolyte extends outward from the first major surface by less than 100 μm.

18. An energy device, comprising:
an electrode comprising lithium cobaltite (LCO) forming a self-supporting, porous sheet with passages, wherein the passages wind and branch through the sheet; and
a solid electrolyte comprising lithium overlaying both a first major surface and a second major surface of the sheet of LCO and extending into the passages,
wherein the energy device is substrate-free such that the sheet of LCO mechanically supports the solid electrolyte, and correspondingly geometrically constrains the solid electrolyte such that an area of a footprint of the solid electrolyte facing the sheet of LCO is not greater than 120% of area of a footprint of the first major surface of the sheet of LCO.

19. The energy device of claim 18 , further comprising a current collector overlaying, directly contacting, and electrically connected to the solid electrolyte.

20. The energy device of claim 18 , wherein the solid electrolyte is binder-free.

21. The energy device of claim 18 , wherein the solid electrolyte overlaying the first major surface of the sheet has a density of at least 90%, and wherein the solid electrolyte mostly consists of inorganic crystalline or amorphous glassy solid electrolyte, as opposed to organic binder, by volume.

22. The energy device of claim 18 , wherein at least some of the passages have a length of at least 10 μm, and wherein the solid electrolyte extends into at least some of the passages a distance of at least 3 μm inward from the first major surface.

23. The energy device of claim 18 , wherein the sheet of LCO has a thickness greater than 10 μm and less than 100 μm, and the solid electrolyte extends outward from the first major surface by less than 100 μm.

24. The energy device of claim 1 , wherein porosity of the sheet of the electrode is at least 15% by volume.

25. The energy device of claim 1 , wherein the solid electrolyte is an amorphous glassy solid electrolyte having a melting temperature above 200° C.

Assignees

• Corning Inc

Inventors

• Badding Michael Edward
• Bayliss Ryan David
• Heine Jennifer Anella
• Tanner Cameron Wayne

Classifications

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• C01G51/42 Primary

  containing alkali metals, e.g. LiCoO2 · CPC title

• H01M4/525 Primary

  of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy · CPC title

• H01M4/131

  Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx · CPC title

• C01P2002/72

  by d-values or two theta-values, e.g. as X-ray diagram · CPC title