Hybrid solid-state cell with a 3d porous cathode structure

Patent metadata

Field	Value
Publication number	US-2024332633-A1
Application number	US-202418737839-A
Country	US
Kind code	A1
Filing date	Jun 7, 2024
Priority date	Jan 31, 2018
Publication date	Oct 3, 2024
Grant date	—

Abstract

An electrochemical cell is provided, which includes a cathode comprising a three dimensional (3D) porous cathode structure, an anode, an electrolyte separator, comprised of a ceramic material, located between the cathode and the anode, and a cathode current collector, wherein the cathode is located between the cathode current collector and the electrolyte separator. The 3D porous cathode structure includes ionically conducting electrolyte strands extending through the cathode from the cathode current collector to the electrolyte separator, pores extending through the cathode from the cathode current collector to the electrolyte separator, and an electronically conducting network extending on sidewall surfaces of the pores from the cathode current collector to the electrolyte separator.

First claim

What is claimed is:

1 . An electrochemical cell comprising:
a cathode; an anode; an electrolyte separator, comprised of a ceramic material, located between the cathode and the anode; and an anode current collector, wherein the anode is located between the anode current collector and the electrolyte separator, wherein the anode comprises a three dimensional (3D) porous anode structure including:
ionically conducting electrolyte strands extending through the anode from the anode current collector to the electrolyte separator;
pores extending through the anode from the anode current collector to the electrolyte separator; and
an electronically conducting network extending on sidewall surfaces of the pores from the anode current collector to the electrolyte separator, and
wherein the cathode is configured to fit precisely into a cathode receptive space.

2 . The electrochemical cell of claim 1 , wherein an upper portion of the cathode receptive space is bounded by a cathode current collector to contact an upper surface of the cathode.

3 . The electrochemical cell of claim 2 , wherein a lower portion of the cathode receptive space is bounded by the electrolyte separator.

4 . The electrochemical cell of claim 3 , wherein side portions of the cathode receptive space are bounded by low-porosity ceramic walls.

5 . The electrochemical cell of claim 4 , wherein the ceramic walls are comprised of solid-state electrolyte material.

6 . The electrochemical cell of claim 4 , wherein the ceramic walls surround at least 60% of side portions of the cathode receptive space.

7 . The electrochemical cell of claim 6 , wherein one side portion of the cathode receptive space includes an opening configured for inserting the cathode into the cathode receptive space.

8 . The electrochemical cell of claim 7 , further comprising a seal configured to seal the opening after the cathode has been inserted into the cathode receptive space.

9 . The electrochemical cell of claim 8 , wherein the cathode is configured to fill the cathode receptive space.

10 . The electrochemical cell of claim 8 , wherein the cathode current collector is comprised of at least one of a metal, a metal alloy, a conductive ceramic or a current conductive carbon based material.

11 . An electrochemical cell comprising:
a cathode; an anode; an electrolyte separator, comprised of a ceramic material, located between the cathode and the anode; and an anode current collector, wherein the anode is located between the anode current collector and the electrolyte separator, wherein the anode comprises a three dimensional (3D) porous anode structure including:
ionically conducting electrolyte strands extending through the anode from the anode current collector to the electrolyte separator;
pores extending through the anode from the anode current collector to the electrolyte separator; and
an electronically conducting network extending on sidewall surfaces of the pores from the anode current collector to the electrolyte separator,
wherein the cathode is a solid or semi-solid cathode comprising a cathode active material, an electrolyte for the charge transfer ion, and an electron conducting material, and
wherein the solid or semi-solid cathode is inserted into a cathode receptive space of the electrochemical cell, and wherein the cathode is configured to precisely fit into the cathode receptive space.

12 . The electrochemical cell of claim 1 , wherein an upper portion of the cathode receptive space is bounded by a cathode current collector to contact an upper surface of the cathode.

13 . The electrochemical cell of claim 12 , wherein a lower portion of the cathode receptive space is bounded by the electrolyte separator.

14 . The electrochemical cell of claim 13 , wherein side portions of the cathode receptive space are bounded by low-porosity ceramic walls.

15 . The electrochemical cell of claim 14 , wherein the ceramic walls are comprised of solid-state electrolyte material.

16 . The electrochemical cell of claim 14 , wherein the ceramic walls surround at least 60% of side portions of the cathode receptive space.

17 . The electrochemical cell of claim 16 , wherein one side portion of the cathode receptive space includes an opening configured for inserting the cathode into the cathode receptive space.

18 . The electrochemical cell of claim 17 , further comprising a seal configured to seal the opening after the cathode has been inserted into the cathode receptive space.

19 . The electrochemical cell of claim 18 , wherein the cathode is configured to fill the cathode receptive space.

20 . The electrochemical cell of claim 8 , wherein the cathode current collector is comprised of at least one of a metal, a metal alloy, a conductive ceramic or a current conductive carbon based material.

Assignees

• Sakuu Corp

Inventors

• Shi Steven Zhichao
• Rogren Philip Eugene

Classifications

• H01M50/112

  Monobloc comprising multiple compartments · CPC title

• H01M50/117

  Inorganic material · CPC title

• H01M4/043

  involving compressing or compaction · CPC title

• H01M2004/024

  Insertable electrodes · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title