Protected lithium electrodes having porous ceramic separators, including an integrated structure of porous and dense Li ion conducting garnet solid electrolyte layers

Patent metadata

Field	Value
Publication number	US-9368775-B2
Application number	US-201414156267-A
Country	US
Kind code	B2
Filing date	Jan 15, 2014
Priority date	Feb 6, 2004
Publication date	Jun 14, 2016
Grant date	Jun 14, 2016

Abstract

Active metal and active metal intercalation electrode structures and battery cells having ionically conductive protective architecture including an active metal (e.g., lithium) conductive impervious layer separated from the electrode (anode) by a porous separator impregnated with a non-aqueous electrolyte (anolyte). This protective architecture prevents the active metal from deleterious reaction with the environment on the other (cathode) side of the impervious layer, which may include aqueous or non-aqueous liquid electrolytes (catholytes) and/or a variety electrochemically active materials, including liquid, solid and gaseous oxidizers. Safety additives and designs that facilitate manufacture are also provided.

First claim

What is claimed is:

1. An electrochemical cell structure, comprising:
an anode comprising a material selected from the group consisting of an active metal, active metal-ion, active metal alloy, active metal alloying metal and active metal intercalating material; and
an ionically conductive protective architecture on a first surface of the anode, the architecture comprising,
an active metal ion conducting separator layer comprising porous glass or ceramic, the separator layer further comprising a non-aqueous anolyte, the separator layer being chemically compatible with the active metal, and in contact with the anode, and
a substantially impervious ionically conductive layer chemically compatible with the separator layer, and in contact with the separator layer.

2. An electrochemical cell structure, comprising:
an anode comprising a material selected from the group consisting of an active metal, active metal-ion, active metal alloy, active metal alloying metal and active metal intercalating material; and
an ionically conductive protective architecture on a first surface of the anode, the architecture comprising,
an active metal ion conducting separator multi-layer that is a composite of at least two layers including a first polymer layer and a second porous ceramic layer, the separator layer further comprising a non-aqueous anolyte, the separator layer being chemically compatible with the active metal, and in contact with the anode, and
a substantially impervious ionically conductive layer chemically compatible with the separator layer, and in contact with the separator layer.

3. The electrochemical cell structure of claim 1 , wherein the active metal is lithium.

4. The electrochemical cell structure of claim 1 , wherein the anode is lithium metal.

5. The electrochemical cell structure of claim 1 , wherein the anode is a lithium alloy.

6. The electrochemical cell structure of claim 1 , wherein the anode is a lithium ion intercalation material.

7. The electrochemical cell structure of claim 6 , wherein the lithium ion intercalation material comprises carbon.

8. The electrochemical cell structure of claim 1 , wherein the anode material comprises silicon as a lithium alloying metal.

9. The electrochemical cell structure of claim 1 , wherein the anolyte comprises a non-aqueous liquid.

10. The electrochemical cell structure of claim 1 , wherein the anolyte comprises a non-aqueous gel electrolyte.

11. The electrochemical cell structure of claim 1 wherein the anolyte comprises a solid polymer electrolyte.

12. The electrochemical cell structure of claim 11 wherein the solid polymer electrolyte is a block co-polymer.

13. The electrochemical cell structure of claim 1 wherein the anolyte comprises an ionic liquid.

14. The electrochemical cell structure of claim 1 wherein the substantially impervious ionically conductive layer comprises a lithium ion conducting oxide.

15. The electrochemical cell structure of claim 13 wherein the lithium ion conducting oxide has a garnet structure.

16. The electrochemical cell structure of claim 1 wherein the porous glass or ceramic is not conductive of lithium ions.

17. The electrochemical cell structure of claim 1 , wherein the porous glass or ceramic is a porous ceramic conductive of lithium ions.

18. The electrochemical cell structure of claim 17 , wherein the porous ceramic is a lithium ion conductive oxide.

19. The electrochemical cell structure of claim 18 , wherein the lithium ion conductive oxide has a garnet structure.

20. The electrochemical cell structure of claim 1 , wherein the architecture is an integrated structure of the porous separator layer integrated with the substantially impervious layer.

21. The electrochemical cell structure of claim 20 , wherein the integrated structure is fabricated by tape casting a multi-layer, wherein one layer is substantially impervious and the opposing integrated layer is porous.

22. The electrochemical cell structure of claim 20 , wherein both the separator layer and the substantially impervious layer of the integrated structure are lithium ion conductors having a garnet structure.

23. The electrochemical cell structure of claim 2 , wherein the active metal is lithium.

24. The electrochemical cell structure of claim 2 , wherein the anode is lithium metal.

25. The electrochemical cell structure of claim 2 , wherein the anode is a lithium alloy.

26. The electrochemical cell structure of claim 2 , wherein the anode is an lithium ion intercalation material.

27. The electrochemical cell structure of claim 26 , wherein the lithium ion intercalation material comprises carbon.

28. The electrochemical cell structure of claim 2 , wherein the anode material comprises silicon as a lithium alloying metal.

29. The electrochemical cell structure of claim 2 , wherein the anolyte comprises a non-aqueous liquid.

30. The electrochemical cell structure of claim 2 , wherein the anolyte comprises a non-aqueous gel electrolyte.

31. The electrochemical cell structure of claim 2 , wherein the anolyte comprises a solid polymer electrolyte.

32. The electrochemical cell structure of claim 31 , wherein the solid polymer electrolyte is a block co-polymer.

33. The electrochemical cell structure of claim 2 , wherein the anolyte comprises an ionic liquid.

34. The electrochemical cell structure of claim 2 , wherein the substantially impervious ionically conductive layer comprises a lithium ion conducting oxide.

35. The electrochemical cell structure of claim 34 , wherein the lithium ion conducting oxide has a garnet structure.

Assignees

• Polyplus Battery Co Inc

Inventors

• Visco Steven J
• Katz Bruce D
• Nimon Yevgeniy S
• De Jonghe Lutgard C

Classifications

• H01M10/36

  Accumulators not provided for in groups H01M10/05-H01M10/34 · CPC title

• H01M8/065

  by dissolution of metals or alloys; by dehydriding metallic substances · CPC title

• H01M6/34

  Immersion cells, e.g. sea-water cells · CPC title

• H01M2300/0085

  Immobilising or gelification of electrolyte · CPC title

• H01M4/628

  Inhibitors, e.g. gassing inhibitors, corrosion inhibitors · CPC title