Compositions and methods for energy storage devices including salts and/or foams

Patent metadata

Field	Value
Publication number	US-2022006071-A1
Application number	US-201917291491-A
Country	US
Kind code	A1
Filing date	Nov 7, 2019
Priority date	Nov 8, 2018
Publication date	Jan 6, 2022
Grant date	—

Abstract

An energy storage device can include a cathode, an anode, and a separator between the cathode and the anode. At least one of the electrodes can include an electrode film prepared by a dry process. The electrode film, the electrode and/or the separator can comprise a salt, improved porosity, increased density, be prelithiated, and/or a foam. Process and apparatuses used for fabricating the electrode and/or electrode film are also described.

First claim

1 . A dry electrode film of an energy storage device, comprising:
a dry active material; a dry binder; and a dry electrolyte salt, wherein the dry electrode film is free-standing.

2 . The dry electrode film of claim 1 , wherein the dry electrolyte salt is selected from LiPF 6 , LiBF 4 , LiBOB, LiN(SO 2 CF 3 ) 2 , LiOSO 2 CF 3 , LiNO 3 , a lithium acetate, a lithium halide, a tetra-alkylammonium tetrafluoroborate, a tetra-alkylammonium hexafluorophosphate, a garnet ion conductor, a sulfur based ion conductor, Li 0.5 La 0.5 TiO 3 (LLTO), Li 7 La 3 Zr 2 O 12 (LLZO), a Lithium Super Ionic Conductor (LISCON), lithium hexafluorophosphate, lithium bis(trifluoromethanesulfonyl)imide, lithium tetrafluoroborate, lithium trifluoromethanesulfonate, lithium perchlorate, lithium bis(trifluoromethane sulfonimide (LiTFSI), lithium bis(oxalato)borate, Li 6.4 La 3 Zr 1.4 Ta 0.6 O 12 , Li 10 SnP 2 S 12 , Li 3 xLa 2/3-x TiO 3 , Li 0.8 La 0.6 Zr 2 (PO 4 ) 3 , Li 1+x Ti 2-x Al x (PO 4 ) 3 , Li 1+x+y Ti 2-x Al x Si y (PO 4 ) 3-y , and LiTi x Zr 2-x (PO 4 ) 3 , and combinations thereof.

3 . The dry electrode film of claim 1 , wherein the dry electrolyte salt comprises 1-10 wt. % of the dry electrode film.

4 . The dry electrode film of claim 1 , wherein the dry electrode film has a thickness of at least 110 μm.

5 . The dry electrode film of claim 1 , wherein the dry electrode film has an electrode film density of at least 0.8 g/cm 3 .

6 . A dry gradient electrode film of an energy storage device, comprising:
a first dry electrode film of claim 1 , comprising a first concentration of the dry electrolyte salt; and a second dry electrode film of claim 1 , comprising a second concentration of an electrolyte salt, wherein the first concentration of the dry electrolyte salt is less than the second concentration of the electrolyte salt.

7 . A solid state energy storage device comprising the dry electrode film of claim 1 , wherein the solid state energy storage device does not comprise a liquid solvent.

8 . An energy storage device comprising the dry electrode film of claim 1 and a solvent contained within a device housing.

9 . The energy storage device of claim 8 , wherein the solvent is a highly volatile solvent.

10 . (canceled)

11 . A method of fabricating a dry electrode film of an energy storage device, comprising:
providing a dry active material, a dry binder, and a dry electrolyte salt; and forming a free standing dry electrode film from the dry active material, the dry binder, and the dry electrolyte salt.

12 . The method of claim 11 , further comprising exposing the dry electrode film to a solvent, thereby dissolving the electrolyte salt.

13 . The method of claim 12 , further comprising placing the dry electrode film into an energy storage device housing, wherein exposing the dry electrode film to a solvent occurs within the energy storage device housing.

14 . The method of any one of claim 12 , further comprising placing the dry electrode film into an energy storage device housing, wherein exposing the dry electrode film to a solvent occurs prior to placing the dry electrode the energy storage device housing.

15 . The method of claim 14 , further comprising prelithiation of the dry electrode film during the step of exposing the dry electrode film to a solvent.

16 . The method of claim 15 , further comprising rolling the lithiated dry electrode.

17 . A foam-active material composite of an energy storage device, comprising:
a dry active material; and a foam.

18 . The material of claim 17 , wherein the foam is a metallic foam, a ceramic foam, and combinations thereof.

19 . The material of claim 17 , wherein the dry active material is encapsulated by the foam.

20 . The material of claim 17 , further comprising a dry binder.

21 . (canceled)

22 . An electrode of an energy storage device comprising the material of claim 17 and without a separate current collector.

23 . (canceled)

24 . A dry composite solid polymer electrolyte (SPE) film of an energy storage device, comprising:
a dry ion conducting polymer; a dry lithium source; a dry binder; an ion conducting medium; and a dry filler material.

25 . The film of claim 24 , wherein the dry ion conducting polymer is selected from polyethylene oxide (PEO), polyvinylidene fluoride (PVDF), poly(methylene oxide), polyoxymethylene, poly(vinyl alcohol) (PVA), poly(vinyl pyrrolidone) (PVP), poly(methyl methacrylate), poly(vinyl acetate), poly(vinylchloride), poly(vinyl acetate), poly(oxyethylene) 9 methacrylate, poly(ethylene oxide) methyl ether methacrylate, and poly(propylenimine), and combinations thereof.

26 . The film of claim 24 , wherein the dry lithium source is selected from lithium perchlorate (LiClO 4 ), lithium tetrafluoroborate (LiBF 4 ), lithium hexafluorophosphate (LiPF 6 ), lithium bis(trifluoromethane sulfonimide) (LiTFSI) (Li(C 2 F 5 SO 2 ) 2 N), lithium bis(oxalato)borate (LiB(C 2 O 4 ) 2 ), lithium trifluoromethanesulfonate (LiCF 3 SO 3 ), lithium bis(pentafluoroethanesulfonyl)imide (C 4 F 10 LiNO 4 S 2 ), lithium bis(fluorosulfonyl)imide (F 2 LiNO 4 S 2 ), lithium difluoro(oxalato) borate (LiBF 2 (C 2 O 4 ), lithium difluorophosphate (F 2 LiO 2 P), lithium oxalyldifluoroborate, lithium trifluorochloroborate (LiBF 3 Cl), lithium hexafluoroarsenate (LiAsF 6 ), Li 6.4 La 3 Zr 1.4 Ta 0.6 O 12 , Li 7 La 3 Zr 2 O 12 , Li 10 SnP 2 S 12 , Li 3 xLa 2/3-x TiO 3 , Li 0.8 La 0.6 Zr 2 (PO 4 ) 3 , Li 1+x Ti 2-x Al x (PO 4 ) 3 , Li 1+x-y Ti 2-x Al x Si y (PO 4 ) 3-y , and LiTi x Zr 2-x (PO 4 ) 3 , and combinations thereof.

27 . The film of claim 24 , wherein the dry filler is selected from titanium oxide (TiO 2 ), silica (SiO 2 ), silicon oxide (SiO), copper oxide (CuO), montmorillonite ((Na,Ca) 0.33 (Al,Mg) 2 (Si 4 O 10 ), bentonite (Al 2 O 34 SiO 2 H 2 O), kaolinite (Al 2 Si 2 O 5 (OH) 4 ), hectorite (Na 0.3 (Mg,Li) 3 Si 4 O 10 (OH) 2 ), and halloysite (Al 2 Si 2 O 5 (OH) 4 ), 4′-Amino-2,3′-dimethylazobenzene (CH 3 C 6 H 4 N═NC 6 H 3 (CH 3 )NH 2 ), yttrium aluminum oxide (Y 3 Al 5 O 12 ), yttrium iron oxide (Y 3 Fe 5 O 12 ) and nanoclay, and combinations thereof.

28 . The film of claim 24 , wherein the ion conducting medium is selected from nanoclay and garnet, and combinations thereof.

29 . (canceled)

30 . (canceled)

Assignees

• Maxwell Lab

Inventors

• Petrowsky Matt
• Shin Joon Ho
• Duong Hieu Minh
• Tapia Vicente

Classifications

• H01M10/0565

  Polymeric materials, e.g. gel-type or solid-type · CPC title

• H01M10/058

  Construction or manufacture · CPC title

• H01G11/56

  Solid electrolytes, e.g. gels; Additives therein · CPC title

• Y02P70/50

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

• H01M10/0525

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