Glassy solid-state electrodes and methods of making glassy solid-state electrodes and battery cells thereof

Patent metadata

Field	Value
Publication number	US-2025219084-A1
Application number	US-202519024530-A
Country	US
Kind code	A1
Filing date	Jan 16, 2025
Priority date	Aug 4, 2020
Publication date	Jul 3, 2025
Grant date	—

Abstract

Batteries, component structures and manufacturing methods, in particular including a glassy embedded battery electrode assembly having a composite material structure composed of interpenetrating material components including a porous electroactive network including a solid electroactive material, and a continuous glassy medium including a Li ion conducting sulfide glass, can achieve enhanced power output, reduced charging time and/or improved cycle life.

First claim

1 . A solid-state battery, comprising:
a positive electrode, comprising a glassy embedded electrode assembly having first and second opposing major surfaces, the electrode assembly comprising:
a composite material structure having a thickness of from about 10 um-1000 um and composed of first and second interpenetrating material components;
wherein the first material component is a porous electroactive network comprising a solid electroactive 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 first portion of a continuous glassy medium comprising a Li ion conducting sulfide glass;
wherein the first portion of the continuous glassy medium extends into the depth of the electroactive network to form a three-dimensional solid-state interface with the electroactive network; and
a negative electrode; and a solid electrolyte separator disposed between the positive and negative electrodes, the solid electrolyte separator comprising a second portion of the continuous glassy medium encapsulating the electroactive network in the form of a glassy cover region that is substantially devoid of crystalline particles.

2 . The solid-state battery of claim 1 wherein the three-dimensional solid-state interface is devoid of reaction products resulting from the Li ion conducting sulfide glass chemically reacting in direct contact with the electroactive material of the network.

3 . The solid-state battery assembly of claim 2 wherein the interface the Li ion conducting sulfide glass is not chemically oxidized in direct contact with the electroactive material of the network.

4 . The solid-state battery of claim 1 wherein the electroactive network is a porous preform electroactive monolith composed of cathode active material that is of intercalation type.

5 . The solid-state battery of claim 1 wherein the electroactive network is a porous preform that is a composite material of discrete electroactive particles held together by a binder material that is thermally stable for utility as a binder when heated to T g of the glassy medium.

6 . The solid-state battery of claim 1 wherein the composite material structure is formed by hot isostatic pressing a mixture of Li ion conducting glassy sulfide media particles and electroactive material particles.

7 . (canceled)

8 . (canceled)

9 . The solid-state battery of claim 1 wherein the electroactive network has an areal capacity of about 0.5 to 10 mAh/cm 2 .

Assignees

• Polyplus Battery Co Inc

Inventors

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

Classifications

• H01M4/0471

  involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis · CPC title

• H01M2004/028

  Positive electrodes · CPC title

• H01M10/0562

  Solid materials · CPC title

• H01M2300/0068

  inorganic · CPC title

• H01M10/0525

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