All sulfide electrochemical cell

Patent metadata

Field	Value
Publication number	US-2021135292-A1
Application number	US-201917251741-A
Country	US
Kind code	A1
Filing date	Jun 14, 2019
Priority date	Jun 15, 2018
Publication date	May 6, 2021
Grant date	—

Abstract

Provided herein are processes for making, and methods of using, solid-state batteries which include sulfide electrolytes in the solid-state separator and in the cathode as a catholyte. The process comprises providing at least two layered stacks, and compressing the at least two layered stacks at a pressure between 30 and 5000 MPa and at a temperature of 50° C. to 250° C. Also set forth herein are electrochemical cells and devices made by these processes.

First claim

What is claimed is:

1 . A process for making a solid-state battery comprising:
providing at least two layered stacks; wherein each layered stack, individually in each instance, comprises a current collector layer having at least one exposed tab and at least one member selected from the group consisting of a positive electrode layer and a solid-state separator layer; and compressing the at least two layered stacks at a pressure in the range of 30 MPa to 5000 MPa and at a temperature of 50° C. to 250° C.

2 . The process of claim 1 , wherein the providing step comprises assembling a layered stack.

3 . The process of claim 1 or 2 , comprising compressing a surface of a positive electrode layer of one of the at least two layered stacks against a surface of a solid-state separator layer of one of the at least two layered stacks.

4 . The process of any one of claims 1 - 3 , comprising calendering at least one of the at least two layered stacks prior to the compressing step.

5 . The process of any one of claims 1 - 4 , wherein at least one layered stack comprises a current collector layer and a positive electrode layer; wherein the current collector layer is in electrical contact with the positive electrode layer.

6 . The process of claim 5 , wherein the current collector layer is a positive electrode current collector layer.

7 . The process of any one of claims 1 - 6 , wherein at least one layered stack comprises a current collector and a solid-state separator layer; wherein the solid-state separator layer is in electrical contact with the current collector.

8 . The process of claim 7 , wherein one of the at least one layered stacks comprises a negative electrode layer.

9 . The process of claim 8 , wherein the negative electrode layer is a lithium (Li) metal electrode layer.

10 . The process of any one of claims 1 - 9 , wherein the positive electrode layer comprises a sulfide single ion conductor and an active material.

11 . The process of any one of claims 1 - 10 , wherein the solid-state separator layer comprises a sulfide single ion conductor.

12 . The process of any one of claims 1 - 11 , wherein the solid-state separator layer comprises LPSI.

13 . The process of any one of claims 5 - 13 , wherein at least one current collector layer comprises a material selected from the group consisting of carbon (C)-coated nickel (Ni), nickel (Ni), copper (Cu), aluminum (Al), and stainless steel.

14 . The process of claim 13 , wherein at least one current collector layer is a negative electrode current collector layer, wherein the negative electrode current collector layer is made of a material selected from the group consisting of carbon (C)-coated nickel (Ni), nickel (Ni), and copper (Cu).

15 . The process of claim 13 or 14 , wherein at least one current collector layer is a positive electrode current collector layer, wherein the positive electrode current collector layer comprises a material selected from the group consisting of carbon (C)-coated aluminum.

16 . The process of claim 14 , wherein the negative electrode current collector layer is C-coated Ni.

17 . The process of any one of claims 1 - 16 , wherein the solid-state separator layer is rectangular shaped.

18 . The process of any one of claims 1 - 17 , wherein the positive electrode layer is rectangular shaped.

19 . The process of any one of claims 1 - 16 wherein the solid-state separator layer is circular shaped.

20 . The process of any one of claim 1 - 16 or 19 , wherein the positive electrode layer is circular shaped.

21 . The process of any one of claims 1 - 20 , wherein the geometric surface area of the positive electrode layer and the geometric surface area solid-state separator layer are substantially the same.

22 . The process of any one of claims 17 - 18 and 21 , wherein one edge of the positive electrode layer is 10 cm in length.

23 . The process of any one of claims 17 - 18 and 21 - 22 , wherein one edge of the solid-state separator layer is 10 cm in length.

24 . The process of any one of claims 19 - 20 , wherein the positive electrode layer has a diameter that is 10 cm in length.

25 . The process of any one of claims 19 - 20 and 24 , wherein the solid-state separator layer has a diameter that is 10 cm in length.

26 . The process of any one of claims 1 - 25 , wherein the solid-state separator layer is a sulfide electrolyte.

27 . The process of claim 26 , wherein the sulfide electrolyte comprises lithium (Li), phosphorus (P), and sulfur (S).

28 . The process of claim 27 , wherein the sulfide electrolyte further comprises iodine (I).

29 . The process of any one of claims 26 - 28 , wherein the sulfide electrolyte further comprises a member selected from the group consisting of Tin (Sn), germanium (Ge), arsenic (As), silicon (Si), chlorine (Cl), bromine (Br), and a combination thereof.

30 . The process of claim 26 , wherein the sulfide electrolyte is LSTPS.

31 . The process of claim 26 , wherein the sulfide electrolyte is LPSI.

32 . The process of any one of claims 1 - 31 , wherein the positive electrode layer comprises a catholyte.

33 . The process of any one of claims 1 - 32 , wherein the positive electrode layer comprises a percolating network of ion conductors.

34 . The process of any one of claims 1 - 33 , wherein the solid-state separator layer comprises a percolating network of ion conductors.

35 . The process of any one of claims 1 - 34 , wherein the solid-state separator comprises a polymer-sulfide composite.

36 . The process of any one of claims 1 - 35 , wherein the positive electrode layer comprises an active material at a mass loading of about 75—about 90% by mass.

37 . The process of claim 36 , wherein the active material comprises a lithium intercalation material, a lithium conversion material, or both a lithium intercalation material and a lithium conversion material.

38 . The process of claim 37 , wherein the intercalation material is selected from the group consisting of a nickel manganese cobalt oxide (NMC), a nickel cobalt aluminum oxide (NCA), Li(NiCoAl)O 2 , a lithium cobalt oxide (LCO), a lithium manganese cobalt oxide (LMCO), a lithium nickel manganese cobalt oxide (LMNCO), a lithium nickel manganese oxide (LNMO), Li(NiCoMn)O 2 , LiMn 2 O 4 , LiCoO 2 , and LiMn 2−a Ni a O 4 , wherein a is from 0 to 2, or LiMPO 4 , wherein M is Fe, Ni, Co, or Mn.

39 . The process of any one of claims 37 - 38 , wherein the lithium conversion material is selected from the group consisting of FeF 2 , NiF 2 , FeO x F 3−2x , FeF 3 , MnF 3 , CoF 3 , CuF 2 , alloys thereof, and combinations thereof.

40 . The process of any one of claim 36 - 39 , wherein the active material is NCA.

41 . The process of any one of claim 36 - 39 , wherein the active material is NMC.

42 . The process of any one of claims 1 - 41 , wherein the positive electrode layer comprises a catholyte at a mass loading of about 10—about 25%.

43 . The process of claim 42 , wherein the catholyte is LSTPS or LSPSCl.

44 . The process

Assignees

• Quantumscape Corp

Inventors

• Holme Tim
• Mair Sunil

Classifications

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• H01M10/0477

  with circular plates · CPC title

• H01M10/052

  Li-accumulators · CPC title

• H01M2300/0068

  inorganic · CPC title

• H01M4/505

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