Electrochemical devices including porous layers

Patent metadata

Field	Value
Publication number	US-11710828-B2
Application number	US-202016879861-A
Country	US
Kind code	B2
Filing date	May 21, 2020
Priority date	May 22, 2019
Publication date	Jul 25, 2023
Grant date	Jul 25, 2023

Abstract

Electrochemical devices that include porous layers, and associated methods, are generally described. In certain cases, the electrochemical device includes a first layer (e.g., a porous coating containing nanoparticles) between an anode and a separator, and a second layer (e.g., another porous coating containing nanoparticles) between a cathode and the separator. The first layer and/or the second layer may have a relatively high porosity, even after the application of an applied pressure to the electrochemical device. The presence of the first layer and the second layer in the electrochemical device may mitigate the occurrence of certain problematic phenomena during cycling of the electrochemical device.

First claim

What is claimed is:

1. An electrochemical device, comprising:
an anode;
a cathode;
a separator between the anode and the cathode;
a first layer between the anode and the separator, the first layer comprising a first plurality of nanoparticles; and
a second layer between the cathode and the separator, the second layer comprising a second plurality of nanoparticles;
wherein:
at least some of the nanoparticles of the first plurality of nanoparticles are in the form of a branched or chain-like structure,
at least some of the nanoparticles of the second plurality of nanoparticles are in the form of a branched or chain-like structure, and
the first plurality of nanoparticles and/or the second plurality of nanoparticles comprise fumed metal oxide particles and/or fumed metalloid oxide particles.

2. The electrochemical device of claim 1 , wherein the first layer and/or the second layer has a porosity of at least 40% after experiencing an applied pressure of at least 12 kg/cm 2 for a period of 14 hours.

3. The electrochemical device of claim 1 , wherein the first layer and the second layer each have a porosity of at least 40%.

4. The electrochemical device of claim 1 , wherein the first layer and the second layer each have a porosity of at least 60%.

5. The electrochemical device of claim 1 , wherein the first layer and the second layer each have a porosity of at least 80%.

6. The electrochemical device of claim 1 , wherein the branched or chain-like structures of the first plurality of nanoparticles comprise aggregates and/or agglomerates of the nanoparticles of the first plurality of nanoparticles and/or wherein the branched or chain-like structures of the second plurality of nanoparticles comprise aggregates and/or agglomerates of the nanoparticles of the second plurality of nanoparticles.

7. The electrochemical device of claim 1 , wherein the branched or chain-like structures of the first plurality of nanoparticles and/or second plurality of nanoparticles have an average length of at least 200 nm and less than or equal to 20 μm.

8. The electrochemical device of claim 1 , wherein the branched or chain-like structures of the first plurality of nanoparticles and/or second plurality of nanoparticles have an aspect ratio of at least 2 and less than or equal to 20.

9. The electrochemical device of claim 1 , wherein the first plurality of nanoparticles and/or second plurality of nanoparticles comprise Si, Al, Ti, Bi, Zn, Cr, Fe, Ge, Ni, Mo, Sn, Zr, V, W, Cu, Mn, Ce, Sb, or a combination thereof.

10. The electrochemical device of claim 1 , wherein the first plurality of nanoparticles and/or the second plurality of nanoparticles comprise SiO 2 .

11. The electrochemical device of claim 1 , wherein the first plurality of nanoparticles and/or the second plurality of nanoparticles comprise aluminum metal.

12. The electrochemical device of claim 1 , wherein the first plurality of nanoparticles and/or the second plurality of nanoparticles comprise a mixture of fumed metal oxide particles and/or fumed metalloid oxide particles and metallic nanoparticles.

13. The electrochemical device of claim 1 , wherein the first plurality of nanoparticles and/or the second plurality of nanoparticles comprise a mixture of fumed silica particles and aluminum nanoparticles.

14. The electrochemical device of claim 1 , wherein the thickness of the first layer and/or the second layer is greater than or equal to 100 nm and less than or equal to 20 μm.

15. The electrochemical device of claim 1 , wherein the first plurality of nanoparticles and/or the second plurality of nanoparticles have a mean maximum cross-sectional dimension of greater than or equal to 20 nm and less than or equal to 1,000 nm.

16. The electrochemical device of claim 1 , wherein the first plurality of nanoparticles and the second plurality of nanoparticles comprise fumed metal oxide particles and/or fumed metalloid oxide particles.

17. An electrochemical device, comprising:
an anode;
a cathode;
a separator between the anode and the cathode;
a first layer between the anode and the separator, the first layer comprising a first plurality of nanoparticles; and
a second layer between the cathode and the separator, the second layer comprising a second plurality of nanoparticles;
wherein:
the first layer and the second layer are porous,
at least some of the nanoparticles of the first plurality of nanoparticles are in the form of a branched or chain-like structure,
at least some of the nanoparticles of the second plurality of nanoparticles are in the form of a branched or chain-like structure, and
the first plurality of nanoparticles and/or the second plurality of nanoparticles are metallic.

Assignees

• Sion Power Corp

Inventors

• Wang Zhongchun
• Coleman David L
• Mikhaylik Yuriy V

Classifications

• H01M4/62 Primary

  Selection of inactive substances as ingredients for active masses, e.g. binders, fillers · CPC title

• H01M4/139

  Processes of manufacture · CPC title

• H01M10/0525

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

• H01M4/366 Primary

  as layered products · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title