Glassy embedded battery electrode assemblies and associated battery cells and methods

Patent metadata

Field	Value
Publication number	US-2024088359-A1
Application number	US-202318463204-A
Country	US
Kind code	A1
Filing date	Sep 7, 2023
Priority date	Sep 9, 2022
Publication date	Mar 14, 2024
Grant date	—

Abstract

Batteries, component structures and manufacturing methods, in particular including a glassy embedded electrode assembly having a solid electrolyte separator layer of a glass or glass ceramic or full ceramic of the garnet type that is fabricated initially as a glass sheet. The glass may be processed from a Ta doped Li7La3Zr2O12 material using glass forming dopants (e.g., by melt quenching and then drawing the glass into the ribbon). The ribbon so formed may be used as a dense solid electrolyte layer if sufficiently conductive, or otherwise heat treated to crystallize a more conductive phase. The solid electrolyte layer may be an oxide or phosphate Li ion conducting solid electrolyte.

First claim

What is claimed is:

1 . A battery cell, comprising:
a negative electrode; and a glassy embedded electrode assembly serving as positive electrode, wherein the electrode assembly has first and second opposing major surfaces, the electrode assembly comprising: a composite material structure composed of first and second interpenetrating material components; wherein the first material component is a porous electroactive network comprising a solid electroactive material of cathode active material, the network having major opposing surfaces and a pore structure with open pores that extend into the network from the major opposing surfaces, the pores having interior pore surfaces; wherein the second material component is a continuous glassy medium comprising a Li ion conducting sulfide glass; wherein the glassy medium encapsulates the electroactive network in the form of a glassy cover region that is substantially devoid of crystalline particles; and wherein the glassy medium extends into the depth of the electroactive network to form a three-dimensional solid-state interface with the electroactive network; and further comprising a dense solid electrolyte layer disposed between the negative electrode and the positive electrode assembly, wherein the dense solid electrolyte layer is an oxide or phosphate Li ion conducting solid electrolyte.

2 . The battery cell of claim 1 wherein the dense solid electrolyte layer is LATP.

3 . The battery cell of claim 1 wherein the dense solid electrolyte layer further comprises an amorphous Li ion conducting film on the surface the solid electrolyte layer and disposed between it and the negative electrode.

4 . The battery cell of claim 3 wherein the amorphous film is an oxide.

5 . The battery cell of claim 4 wherein the amorphous oxide film is deposited by physical vapor deposition onto the surface of the solid electrolyte layer.

6 . The battery cell of claim 5 wherein the physical vapor deposition uses a garnet material as the target.

7 . The battery cell of claim 5 wherein the target has composition Li 7+x−y A x B 3−x C 2−y D y O 12 wherein A is a bivalent cation, B is a trivalent cation, C is a tetravalent cation, and D a pentavalent cation, with 0≤x≤3 (and preferably 0≤x≤2) and 0≤y<2 (and preferably 0≤x<1).

8 . The battery cell of claim 3 wherein the negative electrode comprises Li metal.

Assignees

• Polyplus Battery Co Inc

Inventors

• Visco Steven J
• Nimon Vitaliy
• Petrov Alexei
• Nimon Yevgeniy S
• Katz Bruce D

Classifications

• H01M4/366 Primary

  as layered products · CPC title

• H01M4/13

  Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof · CPC title

• H01M4/382

  Lithium (H01M4/405 takes precedence) · CPC title

• H01M4/62

  Selection of inactive substances as ingredients for active masses, e.g. binders, fillers · CPC title

• H01M10/0562

  Solid materials · CPC title