Use of perforated electrodes in silicon-dominant anode cells

Patent metadata

Field	Value
Publication number	US-12230783-B2
Application number	US-201916676813-A
Country	US
Kind code	B2
Filing date	Nov 7, 2019
Priority date	Nov 7, 2019
Publication date	Feb 18, 2025
Grant date	Feb 18, 2025

Abstract

Systems and methods for use of perforated anodes in silicon-dominant anode cells may include a cathode, an electrolyte, and an anode, where the cathode and anode each comprise an active material on a current collector. One or both of the current collector and active material may be perforated. For example, the current collector may be perforated and/or both the current collector and active material may be perforated. The battery may comprise a stack of anodes and cathodes. Each cathode of the stack may be perforated and/or each anode of the stack may be perforated. Each cathode of the stack may comprise two layers of active material on each side of the cathode where a first of the two layers of active material may be for prelithiation of anodes of the battery. A second of the two layers may be for lithium cycling of the battery.

First claim

What is claimed is:

1. A battery, the battery comprising:
a cathode, an electrolyte, and an anode, the anode comprising active material on a current collector and the cathode comprising first and second current collectors, wherein:
the current collector of the anode and/or the first and second current collector of the cathode are perforated;
the cathode comprises a first active material layer on a first surface of each of the first and second current collectors and a second active material layer on a second surface of the first and second current collectors,
wherein the first active material layer comprises a first type of active material and the second active material layer comprises a second type of active material,
wherein the first and second types of active material includes one or more of lithium cobalt oxide (LCO), lithium iron phosphate, lithium nickel cobalt manganese oxide (NMC), lithium nickel cobalt aluminum oxide (NCA), lithium manganese oxide (LMO), or lithium nickel manganese spinel;
the first active material layer on the first surface of the first current collector and the first active material layer on the first surface of the second current collector are adjacent to each other; and
the first active material layer has a different amount of material per area as the second active material layer, such that the first active material layer is a source of lithiation for prelithiation of silicon-dominant anodes of the battery and the second active material layer is for lithium cycling of the battery, wherein lithium from the first active material layer travels through perforations of the first and second current collector of the cathode during prelithiation,
wherein the cathode is arranged as a top or bottom electrode of a stack of anodes and cathodes, the second active material layer on the second surface of the first and second current collectors being an outermost surface of the cathode opposite the anode.

2. The battery according to claim 1 , wherein the perforations are circular.

3. The battery according to claim 1 , wherein both the current collector and active material are perforated.

4. The battery according to claim 1 , wherein each cathode of the stack is perforated.

5. The battery according to claim 1 , wherein each anode of the stack is perforated.

6. The battery according to claim 1 , wherein outer surfaces of outermost cathodes of the stack comprise active material that prelithiate silicon-dominant anodes in the battery.

7. The battery according to claim 1 , wherein the first active material layer is different than the second active material layer.

8. The battery according to claim 7 , wherein one of the first and second active material layers is for prelithiation of silicon-dominant anodes of the battery and one of the first and second active material layers is for lithium cycling of the battery.

9. The battery according to claim 1 , wherein each cathode of the stack comprises two layers of active material on each side of the cathode.

10. The battery according to claim 9 , wherein a first of the two layers of active material on each side of the cathode is for prelithiation of silicon-dominant anodes of the battery and a second of the two layers on each side of the cathode is for lithium cycling of silicon- dominant anodes of the battery.

11. The battery according to claim 1 , wherein the active material of the anode comprises 50% or greater silicon by weight.

12. The battery according to claim 1 , wherein a formation process of the battery is performed with a less than 1C charge rate.

13. A battery, the battery comprising:
a plurality of cathodes, an electrolyte, and a plurality of anodes, the anodes each comprising an active material on a current collector and the cathodes each comprising first and second current collectors, wherein:
the plurality of cathodes are perforated;
a silicon content of the anodes is at least 50% silicon by weight;
the cathode comprises a first active material layer on a first surface of each of the first and second current collectors and a second active material layer on a second surface of the first and second current collectors;
the first active material layer on the first surface of the first current collector and the first active material layer on the first surface of the second current collector are adjacent to each other,
wherein the first active material layer comprises a first type of active material and the second active material layer comprises a second type of active material,
wherein the first and second types of active material includes one or more of lithium cobalt oxide (LCO), lithium iron phosphate, lithium nickel cobalt manganese oxide (NMC), lithium nickel cobalt aluminum oxide (NCA), lithium manganese oxide (LMO), or lithium nickel manganese spinel; and
the first active material layer has a different amount of material per area as the second active material layer, such that the first active material layer is for prelithiation of silicon-dominant anodes of the battery and the second active material layer is for lithium cycling of the battery, wherein lithium from the first active material layer travels through perforations of the first and second current collector of the cathode during prelithiation,
wherein the cathode is arranged as a top or bottom electrode of a stack of anodes and cathodes, the second active material layer on the second surface of the first current collector being an outermost surface of the stack of anodes and cathodes.

Assignees

• Enevate Corp

Inventors

• Ansari Younes
• Nair Ambica
• Park Benjamin

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M10/0585

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M4/386

  Silicon or alloys based on silicon · CPC title

• H01M4/742 Primary

  perforated material · CPC title

• H01M10/0525

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