All-solid battery and method of preparing the same

Patent metadata

Field	Value
Publication number	US-12243979-B2
Application number	US-202117375162-A
Country	US
Kind code	B2
Filing date	Jul 14, 2021
Priority date	Nov 19, 2020
Publication date	Mar 4, 2025
Grant date	Mar 4, 2025

Abstract

The all-solid battery includes: a cathode layer including a cathode active material layer, an anode layer, and a solid electrolyte layer that is disposed between the cathode layer and the anode layer and includes a solid electrolyte, wherein the anode layer includes a porous anode current collector; a first anode active material layer including a first metal and a carbonaceous anode active material disposed on the porous anode current collector; a conformal coating layer including a second metal disposed on the first anode active material layer, wherein the conformal coating layer of the anode layer is between the first anode active material layer and the solid electrolyte layer, and a surface roughness of the solid electrolyte layer, proximate to the conformal coating layer, is about 2 micrometers or less.

First claim

What is claimed is:

1. An all-solid battery comprising:
a cathode layer comprising a cathode active material layer;
an anode layer; and
a solid electrolyte layer disposed between the cathode layer and the anode layer and comprising a solid electrolyte,

wherein the anode layer comprises
a porous anode current collector,
a first anode active material layer comprising a first metal and a carbonaceous anode active material disposed on the porous anode current collector, and
a conformal coating layer consisting of a second metal disposed on the first anode active material layer, wherein the second metal is silver, copper, iron, magnesium, or a combination thereof,
wherein the conformal coating layer is between the first anode active material layer and the solid electrolyte layer, and
a surface of the solid electrolyte layer proximate to the conformal coating layer has a surface roughness of about 2 micrometers or less,
wherein a porosity of the conformal coating layer is in a range of about 1 percent to about 20 percent, and a pore size of the conformal coating layer is about 20 micrometers or less, and a thickness of the conformal coating layer is about 200 nanometers of less, and
wherein the porous anode current collector, the first anode active material layer, the conformal coating layer, and regions therebetween are Li-free regions, which are free of lithium in an initial state or a state after the all-solid battery is discharged.

2. The all-solid battery of claim 1 , wherein the surface of the solid electrolyte layer proximate to the conformal coating layer has a surface roughness in a range of about 0.1 micrometer to about 2 micrometers.

3. The all-solid battery of claim 1 , wherein a conformality of the conformal coating layer is in a range of about 80 percent to about 100 percent.

4. The all-solid battery of claim 1 , wherein the second metal in the conformal coating layer is silver or copper, or a combination thereof.

5. The all-solid battery of claim 1 , wherein the conformal coating layer is adjacent to the solid electrolyte layer.

6. The all-solid battery of claim 1 , wherein the anode layer is porous, and a porosity of the anode layer decreases in a direction from the porous anode current collector towards the conformal coating layer,
wherein
a porosity of the porous anode current collector is in a range of about 50 percent to about 95 percent,
a porosity of the first anode active material layer is in a range of about 10 percent to about 50 percent,
a porosity of the conformal coating layer is about 5 percent to about 20 percent, and
a pore size of the conformal coating layer is about 0.1 micrometer to about 10 micrometers.

7. The all-solid battery of claim 1 , wherein an electrical conductivity in the anode layer increases in a direction from the first anode active material layer towards the conformal coating layer, and
wherein an electrical conductivity of the first anode active material layer is in a range of about 10 3 siemens per centimeter to about 10 5 siemens per centimeter, and
an electrical conductivity of the conformal coating layer is greater than about 10 5 siemens per centimeter.

8. The all-solid battery of claim 1 , wherein a total content of an amount of the first metal in the anode layer increases in a direction from the first anode active material layer towards the conformal coating layer,
wherein an amount of the first metal in the first anode active material layer is in a range of about 20 weight percent to about 80 weight percent, based on a total weight of the first anode active material layer.

9. The all-solid battery of claim 1 , wherein a porosity of the porous anode current collector is in a range of about 50 percent to about 99 percent, and
the porous anode current collector comprises a pore having a size in a range of about 100 μm to about 2 mm.

10. The all-solid battery of claim 9 , further comprising lithium metal or a lithiophilic material disposed in the pore.

11. The all-solid battery of claim 1 , wherein a thickness of the porous anode current collector is in a range of about 10 micrometers to about 30 micrometers, and
a thickness of the first anode active material layer is in a range of about 10 nanometers to about 10 micrometers.

12. The all-solid battery of claim 1 , wherein a ratio of a thickness of the porous anode current collector relative to a total thickness of the first anode active material layer and the conformal coating layer is in a range of about 2:1 to about 4:1.

13. The all-solid battery of claim 1 , wherein the porous anode current collector comprises at least one of copper, stainless steel, aluminum, nickel, titanium, calcined carbon, surface-treated copper, or surface-treated stainless steel, wherein a surface treatment of the surface-treated copper or surface-treated stainless steel comprises at least one of carbon, nickel, titanium, silver, or an aluminum-cadmium alloy, and
wherein an electrical conductivity of the porous anode current collector is about 10 7 siemens per meter or more.

14. The all-solid battery of claim 1 , further comprising a second anode active material layer between the porous anode current collector and the first anode active material layer.

15. The all-solid battery of claim 1 further comprising a third anode active material layer between the first anode active material layer and the conformal coating layer.

16. The all-solid battery of claim 1 , wherein the first anode active material layer comprises a mixture of the first metal and the carbonaceous anode active material, or is a first metal-carbon composite.

17. The all-solid battery of claim 1 , wherein the first metal of the first anode active material layer is at least one of indium, silicon, gallium, tin, aluminum, titanium, zirconium, niobium, germanium, antimony, bismuth, gold, platinum, palladium, magnesium, silver, or zinc.

18. The all-solid battery of claim 1 , wherein the carbonaceous anode active material comprises amorphous carbon.

19. The all-solid battery of claim 16 , wherein the first anode active material layer comprises the first metal-carbon composite, and the first metal-carbon composite is a composite of first particles comprising amorphous carbon and second particles comprising the first metal,
wherein an amount of the second particles is in a range of about 1 weight percent to about 50 weight percent, based on the total weight of the first metal-carbon composite.

20. The all-solid battery of claim 1 further comprising
a second anode active material layer between the porous anode current collector and the first anode active material layer, and a third anode active material layer between the first anode active material layer and the conformal coating layer,
wherein the second anode active material layer is a metal layer comprising lithium or a lithium alloy.

21. The all-solid battery of claim 1 , wherein the solid electrolyte is an oxide solid electrolyte or a sulfide solid electrolyte.

22. The all-solid battery of claim 21 , wherein the oxide solid electrolyte is at least one of Li 1+x+y Al x Ti 2-x Si y P 3-y O 12 , wherein 0<x<2 and 0≤y<3, BaTiO 3 , Pb(Zr a Ti 1-a )O 3 wherein 0≤a≤1, Pb 1-x La x Zr 1-y Ti y O 3 , wherein 0≤x<1 and 0≤y<1, Pb(Mg 1/3 Nb 2/3 )O 3 —PbTiO 3 , HfO 2 , SrTiO 3 , SnO 2 , CeO 2 , Na 2 O, MgO, NiO, CaO, BaO, ZnO, ZrO 2 , Y 2 O 3 , Al 2 O 3 , TiO 2 , SiO 2 , Li 3 PO 4 , Li x Ti y (PO 4 ) 3 , wherein 0<x<2 and 0<y<3, Li x Al y Ti z (PO 4 ) 3 , wher

Assignees

• Samsung Electronics Co Ltd

Inventors

• Chang Wonseok
• Kim Jusik
• Yoon Gabin
• Lee Myungjin

Classifications

• H01M2300/0071

  Oxides · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M10/0525

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

• H01M4/80

  Porous plates, e.g. sintered carriers · CPC title

• H01M4/667

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