Post-fabrication curing of support system for batteries, fabrication techniques and applications for the same

Patent metadata

Field	Value
Publication number	US-2025006974-A1
Application number	US-202318216384-A
Country	US
Kind code	A1
Filing date	Jun 29, 2023
Priority date	Jun 29, 2023
Publication date	Jan 2, 2025
Grant date	—

Abstract

Methods of fabricating electrochemical cells employing polymeric support systems rather than metal-based materials as a protective mechanism against mechanical and electrical damage include assembling components of the electrochemical cell. In addition to an anode, a cathode, and a porous separator, the components include a continuous network of precursors of a polymer support system. The continuous network is arranged in continuous pathway(s) extending throughout the interior of the electrochemical cell. Batteries may be provided with the continuous network of precursors in place, i.e., uncured, and curing may be performed post-fabrication and/or sale. Alternatively, curing may be performed during fabrication (or prior to sale), resulting in a continuous network of polymeric pathways extending throughout the volume of the cell and providing mechanical strength, e.g., by penetrating and physically coupling the various components of the cell. Curing may be performed using various mechanisms, including thermal, kinetic, chemical, and optical.

First claim

What is claimed is:

1 . A method for fabricating an electrochemical cell, comprising:
assembling a plurality of components of the electrochemical cell, wherein the plurality of components comprises: an anode; a cathode a porous separator, directly ionically coupled or indirectly ionically coupled to the anode and the cathode; and a continuous network of precursors of a polymer support system, the continuous network comprising a plurality of continuous pathways extending from the anode to the cathode, wherein at least some of the continuous pathways penetrate the anode, the porous separator, and the cathode.

2 . The method as recited in claim 1 , wherein the plurality of precursors are selected from the group consisting of:
one or more polymeric precursors; one or more initiators; one or more binders; one or more terminators; one or more crosslinkers; one or more carbonaceous materials; one or more scavenging materials; one or more thermosetting materials; one or more solvent systems; one or more phase change materials; one or more lithium ion transporting compounds; and combinations thereof.

3 . The method as recited in claim 2 , wherein the one or more polymeric precursors are precursors of one or more compounds selected from the group consisting of: polytrimethylene terephthalate, polyethersulfone, high density polyethylene, low density polyethylene, linear low density polyethylene, polypropylene, polyolefin copolymers, polystyrene, polystyrene copolymers, polythene, polyvinyl halides, polyvinyl alcohols, polytetrafluoroethylene (TEFLON®), polyacrylates, polymethacrylates, polyesters, polyvinylchloride, fluoropolymers, polyamides, polyamide-imides, polyether imides, polyphenylene sulfides, polysulfones, polyacetals, polycarbonates, polyphenylene oxides, polyurethanes, thermoplastic elastomers, epoxies, alkyds, melamines, phenolics, ureas, vinyl esters, epoxies, hybridized crosslinking polymers, cyanate esters, polyurethanes, acrylonitric butadiene styrene (ABS) and polyacrylonitrile (PAN); ethylene vinyl alcohol, poly(methyl methacrylate) (PMMA), polyvinyl cinnamate, polyisoprene, polyamides, polyimides, styrenic block copolymers, bitumen, nitrile rubber, polycarbonate, polyetherimide (PEI), poly(pheylene sulfide) (PPS), polyetheretherketone (PEEK), polyetherketones (PEK), and combinations thereof.

4 . The method as recited in claim 2 , wherein the one or more initiators are selected from the group consisting of: moisture-based initiators, exothermic initiators, endothermic initiators, radical-generating compounds, sources of electromagnetic radiation, and combinations thereof.

5 . The method as recited in claim 2 , wherein the one or more binders are selected from the group consisting of: polyacrylate, polyacrylamide (PAM), polyacrylate, polyacrylamide (PAM), cyanoacrylates, aliphatic amines, polyamides, amidoamines, cyclophatic amines, aromatic amines, vinyltrimethoxysilane, and combinations thereof.

6 . The method as recited in claim 2 , wherein the one or more crosslinkers are selected from the group consisting of: amine-based chemicals, polycarbamides, [polyurea], polyamides, dicyandiamide, cycloalpahtic amines, boron trifluoride, amidoamines, aliphatic amines, tetraglycidyldiaminodiphenylmethane, diethyltoluene diamine, aromatic amine curing agents, and combinations thereof.

7 . The method as recited in claim 2 , wherein the one or more carbonaceous materials are selected from the group consisting of: carbon black, graphite, pyrolytic graphite, graphene (preferably three-dimensional graphene (3DG), graphene nanoparticles, and/or graphene platelets), single-walled carbon nanotubes (SWCNT), multi-walled carbon nanotubes (MWCNT), carbon nanotubes, carbon nano-onions (CNOs), necked CNOs, carbon nanospheres, fullerenes, hybrid fullerenes, and combinations thereof.

8 . The method as recited in claim 2 , wherein the one or more scavenging materials are selected from the group consisting of: polypropylene (PP), polyacrylate polyols, phenolic antioxidants, n-octyltriethoxysilane, n-propyltriethoxysilane, trimethylsilyl) isothiocyanate (TMSNCS), aminosilan-based compounds, copper-containing compounds, zinc-containing compounds, iron-containing compounds, polyacrylates, volcanic ash, talc, mica, alumina, silica, cellulose-based materials, metallic reducing agents, metal halides, ascorbic acid, sodium bicarbonate, and combinations thereof.

9 . The method as recited in claim 2 , wherein the one or more thermosetting materials are selected from the group consisting of: epoxies, phenocarboxylic acids, bismaleimides, cyanates, esters, polybenzoxazines, crosslinking polymers, photopolymers, carbon fibers, and combinations thereof.

10 . The method as recited in claim 2 , wherein the one or more solvent systems comprise one or more compounds selected from the group consisting of: dimethyl siloxane (DMSO), tetrabutylammonium hydroxide (TBA), dimethyl formamide (DMF), 1,2-dimethoxyethane (DME), tetrahydrofuran (THF), triethylene glycol dimethyl ether (TEGDME), 2-methyl-2-oxazoline (MOZ), 1,3-Dioxolane (DOL), 3,3-dimethyloxetane (DMO), 2-ethyl-2-oxazoline (EOZ), e-caprolactone (CL), and combinations thereof.

11 . The method as recited in claim 2 , wherein the one or more lithium ion transporting compounds are selected from the group consisting of: palladium (II) oxide, lithium cobalt oxide (LiCoO 2 ), lithium lanthanides, diphenyliodonium hexafluorophosphate (DPIHFP), lithium borohydride (LiBH 4 ) lithium bis(trifluoromethanesulfonyl)imide (LiTFSI) (LiC 2 F 6 NO 4 S 2 ), lithium thiophosphates, NASICON, Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 (LATP)), perovskite, Li 0.5 La 0.5 TiO 3 , (LLTO), lithium azide (Li 3 N), argyrodite (Li 6 PS 5 Cl), and combinations thereof.

12 . The method as recited in claim 1 , comprising:
coating external surface(s) of the electrochemical cell with the precursors of the polymer support system; and curing the precursors to form a casing surrounding the electrochemical cell.

13 . The method as recited in claim 1 , comprising arranging the electrochemical cell in a jelly-roll configuration, wherein the precursors of the polymeric support system are present in interstitial spaces of the jelly-roll configuration.

14 . The method as recited in claim 1 , comprising:
forming one or more interpenetrating support structure precursors within the electrochemical cell, each interpenetrating support structure independently comprising the precursors of the polymer support system; and curing the precursors to form the interpenetrating support structures within the electrochemical cell.

15 . The method as recited in claim 14 , wherein some or all of the interpenetrating support structures each independently comprise a chemical anchor configured to provide mechanical strength to the electrochemical cell and to provide indica of impending mechanical failure of the electrochemical cell.

16 . The method as recited in claim 14 , wherein the interpenetrating support structures are aligned along a direction parallel to a longitudinal axis of the porous separator.

17 . The method as recited in claim 14 , wherein the interpenetrating support structures are aligned along a direction perpendicular to a longitudinal axis of the porous separator.

18 . The method as recited in claim 1 , comprising: curing the plurality of precursors to form the polymer support system.

19 . The method as recited in claim 18 , wherein the curing is driven via one or more chemical reactions.

20 . The

Assignees

• Lyten Inc

Inventors

• Anzelmo Bryce H
• Baucom Jesse
• Favors Zach
• Rhodes Kevin

Classifications

• H01M10/0565

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

• H01M2300/0082

  Organic polymers · CPC title

• H01M50/414

  Synthetic resins, e.g. thermoplastics or thermosetting resins · CPC title

• H01M50/403

  Manufacturing processes of separators, membranes or diaphragms · CPC title

• H01M10/0431 Primary

  Cells with wound or folded electrodes (H01M10/045 takes precedence) · CPC title