Li-ion battery cell using improved anode current collector

Patent metadata

Field	Value
Publication number	US-2024105984-A1
Application number	US-202318361437-A
Country	US
Kind code	A1
Filing date	Jul 28, 2023
Priority date	Jul 28, 2022
Publication date	Mar 28, 2024
Grant date	—

Abstract

A lithium-ion battery and methods thereof are disclosed. In an aspect, the lithium-ion battery includes an anode component, a cathode component, a separator, and an electrolyte. The anode component includes an anode current collector and a respective anode coating on each side of the anode current collector. An anode coating includes composite particles including carbon and silicon. A mass fraction of the silicon in the composite particles of the anode coatings may be in a range of about 5 wt. % to about 70 wt. % of the anode coatings. The anode component undergoes a maximum areal expansion (A max ) during the multiple charging and discharging cycles. The anode current collector comprises a copper foil, the copper foil being characterized, before the respective anode coatings are formed thereon, by an ultimate tensile stress (UTS) and a strain at the UTS (ε UTS ).

First claim

1 . A lithium-ion battery configured to undergo multiple charging and discharging cycles, comprising:
an anode component, comprising an anode current collector and a respective anode coating on each side of the anode current collector; a cathode component, comprising a cathode current collector and a respective cathode coating on each side of the cathode current collector; a separator interposed between the anode component and the cathode component; and an electrolyte infiltrated in the separator between the anode component and the cathode component, wherein: the anode coatings comprise composite particles comprising carbon and silicon, a mass fraction of the silicon in the composite particles of the anode coatings being in a range of about 5 wt. % to about 70 wt. % of the anode coatings; the anode component undergoes a maximum areal expansion (A max ) during the multiple charging and discharging cycles, expressed as a percentage of an area of the anode component before the multiple charging and discharging cycles; the anode current collector comprises a copper foil, the copper foil being characterized, before the respective anode coatings are formed thereon, by an ultimate tensile stress (UTS) and a strain at the UTS (ε UTS ), expressed in %; and the maximum areal expansion and the strain at the UTS are related as follows:
A max ≤ε UTS   (Formula 1).

2 . The lithium-ion battery of claim 1 , wherein:
the maximum areal expansion and the strain at the UTS are related as follows:
A max ≤aε UTS −b   (Formula 2);

a is in a range of about 0.6 to about 1.0; and b is in a range of about 0.0 to about 0.7.

3 . The lithium-ion battery of claim 2 , wherein:
the a is in a range of about 0.6 to about 0.7; and the b is in a range of about 0.6 to about 0.7.

4 . The lithium-ion battery of claim 1 , wherein:
the strain at the UTS is in a range of about 2% to about 18%.

5 . The lithium-ion battery of claim 1 , wherein:
the maximum areal expansion is in a range of about 0.1% to about 6.0%.

6 . The lithium-ion battery of claim 1 , wherein:
the UTS is about 250 MPa or greater.

7 . The lithium-ion battery of claim 1 , wherein:
the mass fraction of the silicon in the composite particles of the anode coatings is in a range of about 15 wt. % to about 40 wt. % of the anode coatings.

8 . The lithium-ion battery of claim 1 , wherein:
the mass fraction of the silicon in the composite particles of the anode coatings is in a range of about 10 wt. % to about 65 wt. % of the anode coatings.

9 . The lithium-ion battery of claim 1 , wherein:
a capacity of the silicon in the composite particles of the anode coatings is in a range of about 500 mAh/g to about 1500 mAh/g.

10 . The lithium-ion battery of claim 1 , wherein:
the copper foil is an electrodeposited copper foil.

11 . The lithium-ion battery of claim 1 , wherein:
the copper foil exhibits a yield strength of about 170 MPa or greater.

12 . The lithium-ion battery of claim 1 , wherein:
a thickness of the copper foil is in a range of about 7 μm to about 12 μm.

13 . The lithium-ion battery of claim 12 , wherein:
the thickness of the copper foil is in a range of about 8 μm to about 10 μm.

14 . The lithium-ion battery of claim 1 , wherein:
an average thickness of the anode coatings is in a range of about 25 μm to about 75 μm.

15 . The lithium-ion battery of claim 1 , wherein:
the anode coatings comprise graphite.

16 . The lithium-ion battery of claim 1 , wherein:
the anode component is a first anode component; the lithium-ion battery comprises a plurality of the first anode components; the cathode component is a first cathode component; the lithium-ion battery comprises a plurality of the first cathode components; and the plurality of the first anode components and the plurality of the first cathode components are stacked along a stacking direction perpendicular to a plane of the plurality of the first anode components and the plurality of the first cathode components, the plurality of the first anode components and the plurality of the first cathode components alternating along the stacking direction.

17 . The lithium-ion battery of claim 16 , wherein:
the lithium-ion battery is configured as a pouch cell, a prismatic cell, or a coin cell.

18 . The lithium-ion battery of claim 1 , wherein:
the anode component, the cathode component, and the separator are wound around a common core.

19 . The lithium-ion battery of claim 18 , wherein:
the lithium-ion battery is configured as a cylindrical cell, a coin cell, or a jelly roll cell.

20 . A method of making a lithium-ion battery configured to undergo multiple charging and discharging cycles, the method comprising:
(A1) providing an anode component comprising an anode current collector and a respective anode coating on each side of the anode current collector; (A2) providing a cathode component comprising a cathode current collector and a respective cathode coating on each side the cathode current collector; and (A3) assembling the lithium-ion battery with a separator interposed between the anode component and the cathode component and an electrolyte infiltrated in the separator between the anode component and the cathode component, wherein: the anode coatings comprise composite particles comprising carbon and silicon, a mass fraction of the silicon in the composite particles of the anode coatings being in a range of about 5 wt. % to about 70 wt. % of the anode coatings; the anode component undergoes a maximum areal expansion (A max ) during the multiple charging and discharging cycles, expressed as a percentage of an area of the anode component before the multiple charging and discharging cycles; the anode current collector comprises a copper foil, the copper foil being characterized, before the respective anode coatings are formed thereon, by an ultimate tensile stress (UTS) and a strain at the UTS (ε UTS ), expressed in %; and the maximum areal expansion and the strain at the UTS are related as follows:
A max ≤ε UTS   (Formula 1).

21 . The method of claim 20 , wherein:
the maximum areal expansion and the strain at the UTS are related as follows:
A max ≤aε UTS −b   (Formula 2);

a is in a range of about 0.6 to about 1.0; and b is in a range of about 0.0 to about 0.7.

22 . The method of claim 21 , wherein:
the a is in a range of about 0.6 to about 0.7; and the b is in a range of about 0.6 to about 0.7.

23 . The method of claim 20 , wherein:
the strain at the UTS is in a range of about 2% to about 18%.

24 . The method of claim 20 , wherein:
the maximum areal expansion is in a range of about 0.1% to about 6.0%.

25 . The method of claim 20 , wherein:
the mass fraction of the silicon in the composite particles of the anode coatings is in a range of about 15 wt. % to about 40 wt. % of the anode coatings.

26 . The method of claim 20 , wherein:
the mass fraction of the silicon in the composite particles of the anode coatings is in a range of about 10 wt. % to about 65 wt. % of the anode coatings.

27 . The method of claim 20 , wherein:
a capacity of the silicon in the composite particles of the anode coatings is in a range of about 500 mAh/g to about 1500 mAh/g.

28 . The method of claim 20 , wherein:
the copper

Assignees

• Sila Nanotechnologies Inc

Inventors

• Parvinian Sepideh
• Bhattacharyya Indrani
• Pavilonis Michael
• Wang Weimin
• Sharma Gaurav Rajpal
• Steiger Jens

Classifications

• H01M10/0525 Primary

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

• H01M4/0404 Primary

  by coating on electrode collectors · CPC title

• H01M10/0587

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

• H01M4/386

  Silicon or alloys based on silicon · CPC title

• H01M4/134

  Electrodes based on metals, Si or alloys · CPC title