Systems and methods for minimizing and preventing dendrite formation in electrochemical cells

Patent metadata

Field	Value
Publication number	US-12580231-B2
Application number	US-202519210930-A
Country	US
Kind code	B2
Filing date	May 16, 2025
Priority date	Dec 16, 2022
Publication date	Mar 17, 2026
Grant date	Mar 17, 2026

Abstract

Embodiments described herein relate to electrochemical cells with dendrite prevention mechanisms. In some aspects, an electrochemical cell can include an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, the cathode having a first thickness at a proximal end of the cathode and a second thickness at a distal end of the cathode, the second thickness greater than the first thickness, a first separator disposed on the anode, a second separator disposed on the cathode, an interlayer disposed between the first separator and the second separator, the interlayer including electroactive material and having a proximal end and a distal end, and a power source electrically connected to the proximal end of the cathode and the proximal end of the interlayer, the power source configured to maintain a voltage difference between the cathode and the interlayer below a threshold value.

First claim

The invention claimed is:

1 . An electrochemical cell, comprising:
an anode; a cathode; a porous material disposed on and in physical contact with the cathode, the porous material substantially free of solid-state electrolyte material, the porous material configured to electrically isolate the anode from the cathode and allow the passage of ions; a solid-state electrolyte layer disposed on and in physical contact with the anode; and an interlayer disposed between the porous material and the solid-state electrolyte layer.

2 . The electrochemical cell of claim 1 , wherein the interlayer includes carbon.

3 . The electrochemical cell of claim 1 , wherein at least one of the porous material or the solid-state electrolyte layer includes a conductive material.

4 . The electrochemical cell of claim 1 , wherein the anode includes lithium metal.

5 . The electrochemical cell of claim 1 , wherein the solid-state electrolyte layer includes a sulfide.

6 . The electrochemical cell of claim 1 , wherein the porous material and the solid-state electrolyte layer have porosities of less than about 1%.

7 . The electrochemical cell of claim 1 , wherein the interlayer includes a binder.

8 . The electrochemical cell of claim 1 , wherein the interlayer includes at least one of activated carbon, hard carbon, soft carbon, conductive carbon particles, carbon black, graphitic carbon, carbon fibers, carbon microfibers, vapor-grown carbon fibers (VGCF), fullerenic carbons including “buckyballs”, carbon nanotubes (CNTs), multiwall carbon nanotubes (MWNTs), single wall carbon nanotubes (SWNTs), graphene, graphene sheets, aggregates of graphene sheets, or materials comprising fullerenic fragments.

9 . The electrochemical cell of claim 1 , wherein the porous layer is a first porous layer and the interlayer is a first interlayer, the electrochemical cell further comprising:
a second interlayer disposed on the first porous layer; and a second porous layer disposed on the second interlayer.

10 . An electrochemical cell, comprising:
an anode; a cathode; a separator disposed on at least one of the anode or the cathode; an interlayer disposed on and in physical contact with the separator, the interlayer including a first conductive material; and a solid-state electrolyte layer disposed on and in physical contact with the interlayer at an interface between the solid-state electrolyte layer and the interlayer, the solid-state electrolyte including a second conductive material different from the first conductive material.

11 . The electrochemical cell of claim 10 , wherein the solid-state electrolyte layer contacts the anode.

12 . The electrochemical cell of claim 11 , wherein the anode includes a lithium metal anode.

13 . The electrochemical cell of claim 11 , wherein an interface between the solid-state electrolyte layer and the anode is substantially free of liquid.

14 . The electrochemical cell of claim 10 , wherein the solid-state electrolyte layer includes a sulfide.

15 . The electrochemical cell of claim 10 , further comprising:
a catholyte in contact with the cathode.

16 . The electrochemical cell of claim 10 , wherein the interlayer includes a binder.

17 . The electrochemical cell of claim 10 , wherein the separator has a porosity of less than about 1%.

18 . The electrochemical cell of claim 10 , wherein the interlayer includes at least one of activated carbon, hard carbon, soft carbon, conductive carbon particles, carbon black, graphitic carbon, carbon fibers, carbon microfibers, vapor-grown carbon fibers (VGCF), fullerenic carbons including “buckyballs”, carbon nanotubes (CNTs), multiwall carbon nanotubes (MWNTs), single wall carbon nanotubes (SWNTs), graphene, graphene sheets or aggregates of graphene sheets, or materials comprising fullerenic fragments.

19 . The electrochemical cell of claim 10 , wherein the separator includes polyethylene.

20 . An electrochemical cell, comprising:
a first electrode; a second electrode; a separator contacting the first electrode; an interlayer contacting the separator, the interlayer including a first electronically conductive material; and a solid-state electrolyte layer coupled to the interlayer opposite the separator, the solid-state electrolyte layer including a second electronically conductive material different from the first electronically conductive material, the second electronically conductive material in physical contact with the first electronically conductive material.

21 . The electrochemical cell of claim 20 , wherein at least one of the separator or the solid-state electrolyte layer includes a conductive material.

22 . The electrochemical cell of claim 21 , wherein the separator includes a non-ionic conductive powder.

23 . The electrochemical cell of claim 20 , wherein the interlayer includes at least one of activated carbon, hard carbon, soft carbon, conductive carbon particles, carbon black, graphitic carbon, carbon fibers, carbon microfibers, vapor-grown carbon fibers (VGCF), fullerenic carbons including “buckyballs”, carbon nanotubes (CNTs), multiwall carbon nanotubes (MWNTs), single wall carbon nanotubes (SWNTs), graphene, graphene sheets, aggregates of graphene sheets, or materials comprising fullerenic fragments.

24 . The electrochemical cell of claim 20 , wherein the second electrode includes at least one of graphite, lithium metal, or silicon.

25 . The electrochemical cell of claim 24 , wherein the second electrode includes lithium metal.

26 . The electrochemical cell of claim 20 , wherein the solid-state electrolyte layer includes a sulfide.

27 . The electrochemical cell of claim 20 , wherein the second electrode contacts the solid-state electrolyte layer.

28 . The electrochemical cell of claim 27 , wherein an interface between the second electrode and the solid-state electrolyte layer is substantially free of liquid.

29 . The electrochemical cell of claim 20 , wherein the interlayer includes a binder.

30 . The electrochemical cell of claim 20 , wherein the separator has a porosity of less than about 1%.

Assignees

• 24M Tech Inc

Inventors

• Chen Junzheng
• Ota Naoki
• Hartzog Chad Alan
• Liu Xiaoming
• Brouwer Michelle Robyn
• D'Angelo Anthony
• Salazar Daniel
• Hans Timothy Allen
• Song Junhua

Classifications

• H02J7/80

  including monitoring or indicating arrangements · CPC title

• H01M4/1395

  of electrodes based on metals, Si or alloys · CPC title

• H01M4/1393

  of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx · CPC title

• H01M4/1391

  of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx · CPC title

• H01M4/134

  Electrodes based on metals, Si or alloys · CPC title