Electrolyte structure for a high-temperature, high-pressure lithium battery

Patent metadata

Field	Value
Publication number	US-12166168-B2
Application number	US-202318154393-A
Country	US
Kind code	B2
Filing date	Jan 13, 2023
Priority date	Jun 2, 2020
Publication date	Dec 10, 2024
Grant date	Dec 10, 2024

Abstract

A system and a method for forming a composite electrolyte structure are provided. An exemplary composite electrolyte structure includes, at least in part, polymer electrolyte preforms that are bonded into the composite electrolyte structure.

First claim

What is claimed is:

1. A composite electrolyte structure, comprising at least, in part, polymer electrolyte preforms that are bonded into the composite electrolyte structure,
wherein the polymer electrolyte preforms comprise polymer electrolyte particles coated with an oxide; and
wherein the composite electrolyte structure further comprises an oxide coating applied over the composite electrolyte structure, wherein the oxide coating applied over the composite electrolyte structure comprises Al 2 O 3 , ZnO, ZrO 2 , CeO 2 , or Al doped ZnO.

2. The composite electrolyte structure of claim 1 , wherein the polymer electrolyte particles comprise poly(vinylidene fluoride)-co-hexafluoropropylene (PVDF-HFP), or poly(ethyleneoxide) (PEO), poly (methylmethacrylate) (PMMA), polyacrylonitrile (PAN), or any combinations thereof.

3. The composite electrolyte structure of claim 1 , wherein the polymer electrolyte particles are coated with an oxide comprising Al 2 O 3 , SiO 2 , ZrO 2 , Y 2 O 3 , or any combinations thereof.

4. The composite electrolyte structure of claim 1 , wherein the polymer electrolyte preforms comprise a binder from a binder jet printer.

5. The composite electrolyte structure of claim 4 , wherein the binder is removed during a bonding process by spark plasma sintering.

6. The composite electrolyte structure of claim 1 , comprising ceramic electrolyte preforms that are bonded into the composite electrolyte structure with the polymer electrolyte preforms.

7. The composite electrolyte structure of claim 6 , wherein the ceramic electrolyte preforms alternate with polymer electrolyte preforms.

8. The composite electrolyte structure of claim 6 , wherein the ceramic electrolyte preforms comprise a binder from a binder jet printer.

9. The composite electrolyte structure of claim 8 , wherein the binder is removed during a bonding process by spark plasma sintering or microwave sintering.

10. The composite electrolyte structure of claim 1 , wherein the oxide coating is applied over the composite electrolyte structure by atomic layer deposition.

11. The composite electrolyte structure of claim 4 , wherein the binder is removed during a bonding process by microwave sintering.

12. The composite electrolyte structure of claim 1 , wherein the polymer electrolyte preforms comprise between about 10 vol. % and about 40 vol. % binder and air.

13. The composite electrolyte structure of claim 1 , wherein the polymer electrolyte preforms have a thickness between about 100 μm and about 700 μm.

14. The composite electrolyte structure of claim 1 , wherein the polymer electrolyte particles have a diameter between about 20 μm and about 1000 μm.

15. The composite electrolyte structure of claim 1 , wherein the polymer electrolyte particles are coated with an oxide having a thickness between about 1 nm and about 100 nm.

16. A composite electrolyte structure, comprising polymer electrolyte preforms that are bonded into the composite electrolyte structure,
wherein the polymer electrolyte preforms comprise polymer electrolyte particles coated with an oxide, and the polymer electrolyte preforms comprise between about 10 vol. % and about 40 vol. % binder and air; and
wherein the composite electrolyte structure further comprises an oxide coating applied over the composite electrolyte structure.

Assignees

• Saudi Arabian Oil Co

Inventors

• Zhan Guodong
• Moellendick Timothy E
• Aljohar Abdulwahab S
• Gooneratne Chinthaka Pasan
• Xu Jianhui

Classifications

• H01M2300/0094

  in the form of layered products, e.g. coatings · CPC title

• H01M2300/0082

  Organic polymers · CPC title

• H01M2300/0074

  Ion conductive at high temperature · CPC title

• H01M10/0525 Primary

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

• C23C16/45525

  Atomic layer deposition [ALD] · CPC title