Rolled Alkali Metal Batteries and Production Process

Patent metadata

Field	Value
Publication number	US-2018323474-A1
Application number	US-201715589629-A
Country	US
Kind code	A1
Filing date	May 8, 2017
Priority date	May 8, 2017
Publication date	Nov 8, 2018
Grant date	—

Abstract

Provided is a rolled alkali metal battery wherein the alkali metal is selected from Li, Na, K, or a combination thereof. The battery comprises an anode, a cathode, an alkali metal ion-conducting separator electronically separating the anode and the cathode, and an alkali metal ion-containing electrolyte in ionic contact with the anode and the cathode, wherein the anode contains a wound roll of an anode active material having an anode roll length, an anode roll width, and an anode roll thickness and/or the cathode contains a wound roll of a cathode active material having a cathode roll length, a cathode roll width, and a cathode roll thickness and wherein the anode roll width and/or the cathode roll width direction is substantially perpendicular to the separator plane.

First claim

We claim:

1 . A rolled alkali metal battery wherein said alkali metal is selected from Li, Na, K, or a combination thereof; said battery comprising an anode, a cathode, an alkali metal ion-conducting separator electronically separating said anode and said cathode, and an alkali metal ion-containing electrolyte in ionic contact with said anode and said cathode, wherein said anode contains a wound roll of an anode active material having an anode roll length, an anode roll width, and an anode roll thickness and/or said cathode contains a wound roll of a cathode active material having a cathode roll length, a cathode roll width, and a cathode roll thickness and wherein said anode roll width and/or said cathode roll width is substantially perpendicular to said separator.

2 . The rolled alkali metal battery of claim 1 , further containing an anode tab connected to or integral with said anode and a cathode tab connected to or integral with said cathode.

3 . The rolled alkali metal battery of claim 1 , further comprising a casing that encloses said anode, said cathode, said separator, and said electrolyte therein to form a sealed battery.

4 . The rolled alkali metal battery of claim 1 , wherein said wound roll of an anode active material contains (a) a layer of supporting solid substrate having two primary surfaces wherein either one or both of said primary surfaces are coated with said anode active material, an optional conductive additive, and an optional binder or (b) a layer of supporting porous substrate having pores that are impregnated with said anode active material, an optional conductive additive, and an optional binder.

5 . The rolled alkali metal battery of claim 1 , wherein said wound roll of a cathode active material contains (a) a layer of supporting solid substrate having two primary surfaces wherein either one or both of said primary surfaces are coated with said cathode active material, an optional conductive additive, and an optional binder or (b) a layer of supporting porous substrate having pores that are impregnated with said cathode active material, an optional conductive additive, and an optional binder.

6 . The rolled alkali metal battery of claim 1 , wherein said alkali metal battery is a lithium metal battery, sodium metal battery, or potassium metal battery and the anode contains a foil or coating of Li, Na, or K metal supported by or coated on a solid or porous supporting substrate.

7 . The rolled alkali metal battery of claim 1 , wherein said alkali metal battery is a lithium-ion battery and said anode active material is selected from the group consisting of:
(a) particles of natural graphite, artificial graphite, meso-carbon microbeads (MCMB), needle coke, carbon particles, carbon fibers, carbon nanotubes, and carbon nano-fibers; (b) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), nickel (Ni), cobalt (Co), manganese (Mn), titanium (Ti), iron (Fe), and cadmium (Cd); (c) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, or Cd with other elements, wherein said alloys or compounds are stoichiometric or non-stoichiometric; (d) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ni, Co, Ti, Mn, or Cd, and their mixtures or composites; (e) pre-lithiated versions thereof; (f) pre-lithiated graphene sheets; and combinations thereof.

8 . The rolled alkali metal battery of claim 1 , wherein said alkali metal battery is a sodium-ion battery and said anode active material contains an alkali intercalation compound selected from petroleum coke, carbon black, amorphous carbon, activated carbon, hard carbon, soft carbon, templated carbon, hollow carbon nanowires, hollow carbon sphere, titanates, NaTi 2 (PO 4 ) 3 , Na 2 Ti 3 O 7 , Na 2 C 8 H 4 O 4 , Na 2 TP, Na x TiO 2 (x=0.2 to 1.0), Na 2 C 8 H 4 O 4 , carboxylate based materials, C 8 H 4 Na 2 O 4 , C 8 H 6 O 4 , C 8 H 5 NaO 4 , C 8 Na 2 F 4 O 4 , C 10 H 2 Na 4 O 8 , C 14 H 4 O 6 , C 14 H 4 Na 4 O 8 , or a combination thereof.

9 . The rolled alkali metal battery of claim 1 , wherein the alkali metal battery is a sodium-ion battery and said anode active material contains an alkali intercalation compound selected from the following groups of materials:
(a) sodium- or potassium-doped silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), cobalt (Co), nickel (Ni), manganese (Mn), cadmium (Cd), and mixtures thereof; (b) sodium- or potassium-containing alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Co, Ni, Mn, Cd, and their mixtures; (c) sodium- or potassium-containing oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides, or antimonides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ti, Co, Ni, Mn, Cd, and mixtures or composites thereof, (d) sodium or potassium salts; and (e) graphene sheets pre-loaded with sodium or potassium.

10 . The rolled alkali metal battery of claim 1 , wherein said cathode active material contains a lithium intercalation compound or lithium absorbing compound selected from the group consisting of lithium cobalt oxide, doped lithium cobalt oxide, lithium nickel oxide, doped lithium nickel oxide, lithium manganese oxide, doped lithium manganese oxide, lithium vanadium oxide, doped lithium vanadium oxide, lithium mixed-metal oxides, lithium iron phosphate, lithium vanadium phosphate, lithium manganese phosphate, lithium mixed-metal phosphates, metal sulfides, metal fluoride, metal chloride, and combinations thereof.

11 . The rolled alkali metal battery of claim 1 , wherein said cathode active material contains a sodium intercalation compound or a potassium intercalation compound selected from NaFePO 4 , Na (1-x) K x PO 4 , KFePO 4 , Na 0.7 FePO 4 , Na 1.5 VOPO 4 F 0.5 , Na 3 V 2 (PO 4 ) 3 , Na 3 V 2 (PO 4 ) 2 F 3 , Na 2 FePO 4 F, NaFeF 3 , NaVPO 4 F, KVPO 4 F, Na 3 V 2 (PO 4 ) 2 F 3 , Na 1.5 VOPO 4 F 0.5 , Na 3 V 2 (PO 4 ) 3 , NaV 6 O 15 , Na x VO 2 , Na 0.33 V 2 O 5 , Na x CoO 2 , Na 2/3 [Ni 1/3 Mn 2/3 ]O 2 , Na x (Fe 1/2 Mn 1/2 )O 2 , Na x MnO 2 , λ-MnO 2 , Na x K (1-x) MnO 2 , Na 0.44 MnO 2 , Na 0.44 MnO 2 /C, Na 4 Mn 9 O 18 , NaFe 2 Mn(PO 4 ) 3 , Na 2 Ti 3 O 7 , Ni 1/3 Mn 1/3 Co 1/3 O 2 , Cu 0.56 Ni 0.44 HCF, NiHCF, Na x MnO 2 , NaCrO 2 , KCrO 2 , Na 3 Ti 2 (PO 4 ) 3 , NiCo 2 O 4 , Ni 3 S 2 /FeS 2 , Sb 2 O 4 , Na 4 Fe(CN) 6 /C, NaV 1-x Cr x PO 4 F, Se z S y , y/z=0.01 to 100, Se, sodium polysulfide, sulfur, Alluaudites, or a combination thereof, wherein x is from 0.1 to 1.0.

12 . The rolled alkali metal battery of claim 1 , wherein said electrolyte contains a lithium salt or sodium salt dissolved in a liquid solvent and/or a polymer and wherein said liquid solvent is water, an organic solvent, an ionic liquid, or a mixture of an organic solvent and an ionic liquid.

13 . The rolled alkali metal battery of claim 1 , wherein said roll of anode active material has a width no less than 500 μm, said anode active material has a mass loading no less than 25 mg/cm 2 and/or occupies at least 25% by weight or by volume of the entire battery cell, and/or the cathode active material has a mass loading no less than 20 mg/cm 2 for an organic or polymer material or no less than 40 mg/cm 2 for an inorganic and non-polymer material in said cathode and/or occupies at least 40% by weight or by volume of the entire battery cell.

14 . The rolled alkali metal battery of claim 1 , wherein said roll of anode active material has a width no less than 1000 μm or 1 mm, and/or said anode active material has a mass loading no

Assignees

• Nanotek Instruments Inc

Inventors

• Liu Chueh
• Zhamu Aruna
• Jang Bor Z

Classifications

• H01M10/054 Primary

  Accumulators with insertion or intercalation of metals other than lithium, e.g. with magnesium or aluminium · CPC title

• H01M2004/025

  with shapes other than plane or cylindrical · CPC title

• H01M4/5825

  Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines · CPC title

• H01M10/0587 Primary

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

• H01M4/60

  of organic compounds · CPC title