Ion permeable composite current collectors for metal-ion batteries and cell design using the same

Patent metadata

Field	Value
Publication number	US-12080883-B2
Application number	US-202117332732-A
Country	US
Kind code	B2
Filing date	May 27, 2021
Priority date	May 29, 2014
Publication date	Sep 3, 2024
Grant date	Sep 3, 2024

Abstract

A Li-ion battery cell, among other materials, components, and techniques, is provided that includes ion-permeable anode and cathode electrodes, an electrolyte ionically coupling the anode and the cathode, a separator electrically separating the anode and the cathode, and a sacrificial, high-capacity Li composition for providing Li to at least one of the electrodes.

First claim

The invention claimed is:

1. A Li-ion battery cell, comprising:
a composite current collector comprising pores;
a second current collector;
a Li-ion permeable anode on the composite current collector;
a Li-ion permeable cathode on the second current collector;
an electrolyte comprising an organic solvent ionically coupling the anode and the cathode; and
a separator electrically separating the anode and the cathode;
wherein the anode comprises a composite active material composition, the composite active material composition comprising first active material particles that exhibit specific capacity of at least 400 mAh/g and second active material particles comprising graphite that exhibit specific capacity that is less than or equal to 372 mAh/g; and
wherein at least some of the second active material particles are in the pores of the composite current collector as part of a filler material;
wherein at least some of the first active material particles are electrically connected to the composite current collector and are outside of the pores of the composite current collector; and
wherein the pores are smaller than the first active material particles.

2. The Li-ion battery cell of claim 1 , wherein the anode comprises Si.

3. The Li-ion battery cell of claim 1 , further comprising:
a high-capacity Li composition for providing Li ions to the anode and/or the cathode;
wherein the high-capacity Li composition exhibits a volumetric capacity in excess of 1000 mAh/cc.

4. The Li-ion battery cell of claim 1 , wherein the Li-ion battery cell is a cylindrical cell.

5. The Li-ion battery cell of claim 1 , wherein the Li-ion battery cell is a pouch cell or a prismatic cell.

6. The Li-ion battery cell of claim 1 , wherein the composite current collector comprises a metal, and the metal is Cu.

7. The Li-ion battery cell of claim 1 , wherein the second current collector comprises a metal, and the metal is Al.

8. The Li-ion battery cell of claim 1 , wherein the composite current collector is produced using a process that comprises electrodeposition.

9. The Li-ion battery cell of claim 1 , wherein the filler material is separate from the electrolyte, ionically conductive and Li ions are permeable through the composite current collector at least via the filler material.

10. The Li-ion battery cell of claim 1 , wherein the filler material further comprises a polymer filler, a conductive carbon filler, and/or a ceramic filler.

11. The Li-ion battery cell of claim 1 , wherein the filler material further comprises a polymer filler comprising polymer fibers.

12. The Li-ion battery cell of claim 1 , wherein:
the filler material further comprises a polymer filler comprising a polymer; and
the polymer includes repeating units selected from ethylene glycol, butadiene, acrylonitrile, acrylate, and methacrylate.

13. The Li-ion battery cell of claim 1 , wherein:
the filler material further comprises a polymer filler; and
the polymer filler is swellable in the organic solvent.

14. The Li-ion battery cell of claim 1 , wherein:
the filler material further comprises a polymer filler; and
the polymer filler exhibits ionic conductivity of at least 10-6 S/cm when exposed to the Li-ion battery cell electrolyte.

15. The Li-ion battery cell of claim 1 , wherein:
the filler material further comprises a conductive carbon filler; and
the conductive carbon filler comprises carbon fibers, carbon nanotubes, graphene, or any combination thereof.

16. The Li-ion battery cell of claim 1 , wherein:
the filler material further comprises a ceramic filler; and
the ceramic filler comprises a solid electrolyte material.

17. The Li-ion battery cell of claim 1 , wherein:
the filler material further comprises a ceramic filler; and
the ceramic filler comprises ceramic particles of an elongated shape.

18. The Li-ion battery cell of claim 1 , wherein the composite current collector (i) exhibits a thickness below about 20 microns and (ii) comprises pores or through channels making up from about 1% to about 20% of a cross-sectional area of the composite current collector.

19. The Li-ion battery cell of claim 1 , wherein the composite current collector comprises pores with a size in the range of about 0.01 to about 20 microns.

20. The Li-ion battery cell of claim 1 , wherein the composite current collector comprises a porous metal that comprises the pores.

21. The Li-ion battery cell of claim 1 , wherein the composite current collector comprises a polymer.

Assignees

• Sila Nanotechnologies Inc

Inventors

• Yushin Gleb
• Berdichevsky Eugene Michael
• Zdyrko Bogdan
• Jacobs Alexander Thomas

Classifications

• H01M4/364

  as mixtures · CPC title

• H01M4/661

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

• H01M4/66

  Selection of materials · CPC title

• H01M4/668

  Composites of electroconductive material and synthetic resins · CPC title

• H01M4/366

  as layered products · CPC title