Composite bilayer coatings for high capacity cathodes and anodes

Patent metadata

Field	Value
Publication number	US-2019341618-A1
Application number	US-201815968314-A
Country	US
Kind code	A1
Filing date	May 1, 2018
Priority date	May 1, 2018
Publication date	Nov 7, 2019
Grant date	—

Abstract

An electrode comprises an electrode core. A composite bilayer coating is conformally disposed on the electrode core. The composite bilayer coating comprises a first layer disposed on at least a portion of the electrode core. The first layer comprises a metal fluoride, a metal oxide or a metal sulfide. A second layer is disposed on the first layer and comprises a metal fluoride, a metal oxide or a metal sulfide.

First claim

What is claimed is:

1 . An electrode, comprising:
an electrode core, and a composite bilayer coating conformally disposed on at least a portion of the electrode core, the composite bilayer coating comprising:
a first layer disposed on at least the portion of the electrode core, the first layer comprising a metal fluoride, a metal oxide or a metal sulfide, and
a second layer disposed on the first layer, the second layer comprising a metal fluoride, a metal oxide or a metal sulfide.

2 . The electrode of claim 1 , wherein the metal fluoride comprises at least one of Mg x F y , Al x F y , Li x F y , Al x F y W z or Al x F y W z C a , where x, y, z and a are greater than 0.

3 . The electrode of claim 1 , wherein the metal oxide comprises at least one of Al x O y , MgO xy or Zr x O y , where x and y are greater than 0.

4 . The electrode of claim 1 , wherein the metal sulfide comprises at least one of Li x S y or Mo x S y , where x and y are greater than 0.

5 . The electrode of claim 1 , wherein the electrode comprises a cathode, and wherein the electrode core comprises one of a lithium-magnesium rich layered-layered, or layered-layered-spinel, a LiCoO 2 , a LiMnNiCoO 2 (NMC, e.g., LiN 1/3 Mn 1/3 CO 1/3 O 2 , LiNi 0.8 Mn 0.1 Ni 0.1 O 2 ) or a Li[Li 0.19 Mn 0.57 Ni 0.16 Co 0.08 ]O 2 .

6 . The electrode of claim 1 , wherein the electrode comprises an anode, and wherein the electrode core comprises graphite.

7 . The electrode of claim 1 , wherein the composite bilayer coating has a thickness of less than 1 nm.

8 . An electrochemical cell, comprising:
a cathode comprising:
a cathode core, and
a cathode composite bilayer coating conformally disposed on at least a portion of the cathode core, the cathode composite bilayer coating comprising:
a cathode first layer disposed on at least the portion of the cathode core, the cathode first layer comprising a metal fluoride, a metal oxide or a metal sulfide, and
a cathode second layer disposed on the cathode first layer, the cathode second layer comprising a metal fluoride, a metal oxide or a metal sulfide;

an anode; and a separator disposed between the cathode and the anode.

9 . The electrochemical cell of claim 8 , wherein the metal fluoride comprises at least one of Mg x F y , Al x F y , Li x F y , Al x F y W z or Al x F y W z C a , where x, y, z and a are greater than 0.

10 . The electrochemical cell of claim 8 , wherein the metal oxide comprises at least one of Al x O y , MgO xy or Zr x O y , where x and y are greater than 0.

11 . The electrochemical cell of claim 8 , wherein the metal sulfide comprises at least one of Li x S y or Mo x S y , where x and y are greater than 0.

12 . The electrochemical of claim 8 , wherein the cathode core comprises one of a lithium-magnesium rich layered-layered spinel, a LiCoO 2 , a LiN 1/3 Mn 1/3 Co 1/3 O 2 or a Li[Li 0.19 Mn 0.57 Ni 0.16 Co 0.08 ]O 2 .

13 . The electrochemical cell of claim 8 , wherein the anode comprises:
an anode core, and an anode composite bilayer coating conformally disposed on at least a portion of the anode core, the anode composite bilayer coating comprising:
an anode first layer disposed on at least the portion of the anode core, the anode first layer comprising a metal fluoride, a metal oxide or a metal sulfide, and
an anode second layer disposed on the anode first layer, the anode second layer comprising a metal fluoride, a metal oxide or a metal sulfide.

14 . The electrochemical cell of claim 13 , wherein the anode core comprises graphite.

15 . The electrode of claim 8 , wherein the cathode composite bilayer coating has a thickness of less than 1 nm.

16 . A method, comprising:
providing an electrode comprising an electrode core; performing A atomic layer deposition cycles of a first precursor material comprising a metal precursor at a first deposition temperature on the electrode; performing B atomic layer deposition cycles of a second precursor material comprising one of a fluoride, an oxide or a sulfide precursor at a second deposition temperature on the electrode; performing C atomic layer deposition cycles of a third precursor material comprising a metal precursor at a third deposition temperature on the electrode; and performing D atomic layer deposition cycles of a fourth precursor material comprising one of a fluoride, an oxide or a sulfide precursor at a fourth deposition temperature on the electrode, wherein the respective atomic layer deposition cycles form a conformal bilayer coating on at least a portion of the electrode core, the composite bilayer coating comprising:
a first layer disposed on at least the portion of the electrode core, the first layer comprising a metal fluoride, a metal oxide or a metal sulfide, and
a second layer disposed on the first layer, the second layer comprising a metal fluoride, a metal oxide or a metal sulfide.

17 . The method of claim 16 , wherein the second precursor material is formulated to react with the first precursor material to form the first layer, and wherein the fourth precursor material is formulated to react with the third precursor material to form the second layer.

18 . The method of claim 16 , wherein each of the first deposition temperature, the second deposition temperature, the third deposition temperature and the fourth temperature is in a range of 50-200 degrees Celsius.

19 . The method of claim 16 , wherein the metal fluoride comprises at least one of Mg x F y , Al x F y , Li x F y , Al x F y W, or Al x F y W z C a , where x, y, z and a are greater than 0.

20 . The method of claim 16 , wherein the metal oxide comprises at least one of Al x O y , MgO xy or Zr x O y , where x and y are greater than 0.

21 . The method of claim 16 , wherein the metal sulfide comprises at least one of Li x S y or Mo x S y , where x and y are greater than 0.

Assignees

• Uchicago Argonne Llc

Inventors

• Mane Anil U
• Croy Jason R
• Elam Jeffrey W
• Balasubramanian Mahalingam

Classifications

• H01M4/505

  of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy · CPC title

• H01M4/1391

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

• H01M4/628 Primary

  Inhibitors, e.g. gassing inhibitors, corrosion inhibitors · CPC title

• H01M4/366 Primary

  as layered products · CPC title

• H01M4/483

  for non-aqueous cells (H01M4/485 takes precedence) · CPC title