WO2001017052A2 - All-solid-state electrochemical device and method of manufacturing - Google Patents
All-solid-state electrochemical device and method of manufacturing Download PDFInfo
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- WO2001017052A2 WO2001017052A2 PCT/US2000/022917 US0022917W WO0117052A2 WO 2001017052 A2 WO2001017052 A2 WO 2001017052A2 US 0022917 W US0022917 W US 0022917W WO 0117052 A2 WO0117052 A2 WO 0117052A2
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- H—ELECTRICITY
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- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/32—Wound capacitors
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- H—ELECTRICITY
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- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/056—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
- H01M10/0564—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of organic materials only
- H01M10/0565—Polymeric materials, e.g. gel-type or solid-type
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- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
- H01M2004/029—Bipolar electrodes
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- H—ELECTRICITY
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- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/50—Current conducting connections for cells or batteries
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M6/00—Primary cells; Manufacture thereof
- H01M6/04—Cells with aqueous electrolyte
- H01M6/06—Dry cells, i.e. cells wherein the electrolyte is rendered non-fluid
- H01M6/10—Dry cells, i.e. cells wherein the electrolyte is rendered non-fluid with wound or folded electrodes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M6/00—Primary cells; Manufacture thereof
- H01M6/14—Cells with non-aqueous electrolyte
- H01M6/16—Cells with non-aqueous electrolyte with organic electrolyte
- H01M6/162—Cells with non-aqueous electrolyte with organic electrolyte characterised by the electrolyte
- H01M6/168—Cells with non-aqueous electrolyte with organic electrolyte characterised by the electrolyte by additives
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M6/00—Primary cells; Manufacture thereof
- H01M6/14—Cells with non-aqueous electrolyte
- H01M6/18—Cells with non-aqueous electrolyte with solid electrolyte
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M6/00—Primary cells; Manufacture thereof
- H01M6/14—Cells with non-aqueous electrolyte
- H01M6/18—Cells with non-aqueous electrolyte with solid electrolyte
- H01M6/188—Processes of manufacture
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M6/00—Primary cells; Manufacture thereof
- H01M6/40—Printed batteries, e.g. thin film batteries
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49108—Electric battery cell making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49108—Electric battery cell making
- Y10T29/49112—Electric battery cell making including laminating of indefinite length material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49108—Electric battery cell making
- Y10T29/49115—Electric battery cell making including coating or impregnating
Definitions
- the present invention generally relates to the manufacture of solid state electrochemical cells, particularly high energy density cells having very thin electrode and electrolyte structures for building ultra-thin laminar batteries.
- the invention also relates to lithium polymer electrolyte batteries containing such electrochemical cells and to their methods of making.
- Lithium rechargeable batteries are the focus of intense investigation around the world because of the rapid proliferation of portable electronic devices in the international marketplace.
- the specific energy and energy density of the lithium ion battery is usually about 125 Wh/kg and 260 Wh/1.
- the packaged battery in a hard plastic case
- the cycle life (number of times the battery can be recharged) of this battery is about 500 to 800 cycles
- the self-discharge (i.e. loss of capacity on standing) per month is about 10%
- cost is about $1 per Watt-hour of energy.
- PVDF is non-conducting and so its sole function is to hold the liquid organic solvent(s) in its structure in a manner similar to a sponge holding water. Because the technology uses an electrolyte solvent absorbed in a polymer, it is not easy to manufacture cells in high speed. Automation of this technology may be very difficult. It is believed the energy densities (gravimetric and volumetric) for this type of battery are lower than the existing lithium ion batteries, cycle life is not too impressive, and cell cost is several dollars per Watt-hour. The physical forms the lithium ion polymer cell could take was a heavily advocated feature, but today only flat prismatic cells are typically manufactured.
- Another rechargeable lithium battery system uses a lithium metal as the negative electrode instead of carbon, and so the energy density of this system can be increased tremendously because of the very high specific capacity of metallic lithium compared to carbon. Gravimetric specific energy density as high as 200 to 250 Wh/kg have been reported in the literature for rechargeable lithium metal batteries. Lithium metal anode batteries are not new. Primary, non-rechargeable batteries using lithium metal, non-aqueous organic electrolytes and a positive electrode have been used in many applications for the past 25 years despite the fact that lithium metal is thermodynamically unstable in liquid organic solvents and reacts with the solvent irreversibly.
- liquid solvent electrolyte in any of the above cell systems is often corrosive and toxic and presents handling difficulties through spillage or leakage from the cell. It can also outgas during overcharge or overdischarge or at elevated temperatures, leading to safety problems. Most of the problems have been associated with the electrode/electrolyte interface.
- Inorganic conducting and non-conducting fillers have also been used to increase the ionic conductivity and mechanical property of the polymer.
- Addition of alpha alumina to (PEO) 8 .LiClO 4 resulted in a negligible effect on the ionic conductivity but dramatically increased the mechanical property at 100°C, while the addition of other ceramic materials such as ionically conductive beta alumina to PEO-Nal and PEO-LiClO 4 complexes improved the ionic conductivity of PEO based electrolytes to about 10 "5 S/cm.
- inorganic fillers based on high surface area alumina and silica have been used to enhance the ionic conductivity of lithium iodide solid electrolyte from 10 "7 S/cm to IO "5 - 10 "4 S/cm at room temperature (see CC. Liang, J. Electrochemical Society, Vol. 120, page 1289 (1973)).
- Advanced commercial battery technologies such as the lithium ion (Sony type), THINFILMTM lead-acid (Bolder Battery Co.), and nickel-metal hydride batteries do not demonstrate very high cycle life, i.e., several tens of thousands of cycles. This is due primarily to considerable phase changes and composite structure segregation that take place within the electrode, inefficient materials utilization and particle movements, and expansion and contraction during charge and discharge.
- batteries such as these do represent a breakthrough in the design of lithium ion batteries and yielded higher cycle life than was previously available by their use of relatively thin electrode structures.
- the THINFILMTM lead-acid battery for high power applications is a good example of thin electrode structures and good materials utilization, but the electrode is still not thin enough to achieve a cycle life of several thousand. Hence, a major drawback of these batteries is that the liquid electrolytes necessarily limit their cycle life.
- lithium ion battery construction In lithium ion batteries the carbon anode is pasted in relatively thin film form onto a copper foil electrode and the lithiated metal oxide cathode is pasted onto an aluminum foil.
- the substrate thickness for both anode and cathode is in a range from about 25 to 35 microns, and the active electrode is about 25 microns thick. Additionally, the length of each electrode in a typical AA size cell is about twice that of lithium anode cells.
- Present day electrode/electrolyte component thickness in gelled electrolyte lithium ion cells is of the order of 50 to 75 microns each. This remains far too thick for optimum electrode utilization and high rate capability.
- Metallic current collectors are also used, not only adding weight but unwanted thickness to the battery.
- the thick electrode concept in commercial cells is designed for maximum capacity, while the thick gelled PVDF electrolyte provides ease of handling.
- the internal resistance of this battery is still relatively higher than its liquid electrolyte counterpart, thus decreasing battery performance.
- Cells constructed from such a design cannot be used at high discharge and charge rates.
- Thick inactive substrates used in such cell construction effectively reduce the energy density of the battery.
- this design exposes the cells to risk of high polarization during charge and discharge, which could lead to breakdown of the liquid solvent electrolyte and consequently loss of capacity, loss of cycle life and inadequate safety.
- an existing lead acid battery designed for an electric car can only provide about 60 to 80 miles range before recharge is not suitable either.
- Known lithium ion batteries are neither cost-effective nor safe for electric vehicles.
- consumers are generally unwilling to pay a premium price for an electric vehicle while gasoline vehicles remain far less expensive to operate.
- the price of the battery can be reduced, and the mileage range of the electric vehicle can be increased to a value closer to the mileage range of a conventional vehicle, the electric vehicle will become quite feasible for widespread use.
- Another problem with existing rechargeable batteries, even those used in small electronic devices, is that they contain liquid organic solvents that have been found to be relatively unsafe for consumer use.
- batteries containing the polymer electrolytes with liquid organic solvents actually tend to lose performance over time, primarily because of cell orientation related problems.
- a battery standing upright will tend to have the liquid solvents travel to the bottom of the cell, and during charge and discharge, the current along the cell height will be different because of the difference in the conductivity at the bottom of the electrode and at the top.
- Such cells do not have very high cycle life and lose capacity as a result of poor charging and discharging.
- LiI-Li 2 S-P S 5 and LiI-Li 2 S-B 2 S 3 exhibit lithium ion conductivities of about 1 x 10 "3 S/cm and 2 x 10 "3 S/cm at room temperature, respectively, for bulk electrolytes. Since the electrolyte is very hard and brittle, it is usually used in a vapor deposited form in very thin films so as to achieve a continuous uniform thickness. Lithium anode batteries based on thin film glassy electrolytes with electrolyte thickness of one to several microns have demonstrated current densities of several tens to hundreds of microamperes per square centimeter at room temperature. Unfortunately, the fabrication of these batteries requires extremely sophisticated deposition equipment and production feasibility and performance of large cells have not yet been demonstrated.
- New all-solid-state laminar electrochemical cells, anodes, cathodes, electrodes and half-electrodes, bipolar units, batteries and methods according to the present invention overcome many of the difficulties and disadvantages associated with conventional electrochemical devices and their methods of making.
- Certain prefened electrochemical cells and batteries of the present invention avoid many of the kinetic constraints on the specific power, cycling efficiency and capacity utilization that are typical of electrochemical devices employing conventional polymer electrolytes and electrodes.
- a kinetic constraint is, for example, the inability to discharge at high rates leading to polarization losses.
- the lithium solid polymer electrolytes employed in the cells and batteries of certain preferred embodiments of the present invention are suitable for use at room temperature, and even below, due to their high ionic conductivity compared to previous lithium polymer electrolytes. Not only are these new electrolytes highly conductive, they are also strong enough to be manufactured by high speed roll-to-roll techniques.
- One advantage of the preferred anodes, cathodes, electrodes and half-electrodes, bipolar units, electrochemical cells and batteries of the present invention is that they employ a thermodynamically stable dry polymer electrolyte that can be manufactured using high speed extrusion or deposition techniques, according to certain preferred methods of the invention.
- the preferred ultra-thin battery embodiments of the present invention overcome those drawbacks by incorporating very thin electrode and electrolyte structures, based on ultra thin film active and inactive components in long lengths. This effectively increases the surface area of the active plates. As a consequence, these new batteries have a higher current drain capability, lower resistance, higher energy content, lower self-discharge rate, and a wider operating temperature range than presently available solid state batteries.
- the prefened batteries of the present invention are orientation tolerant, operating optimally in any configuration without regard to their vertical or horizontal positioning.
- the new rechargeable batteries also provide freedom from dendrite formation, higher efficiency, lower internal resistance, greater capacity utilization, higher cycle life or cyclability, and better reliability and safety than previously available in a rechargeable metal ion battery. Moreover, these batteries are better able to tolerate overcharge and will not lead to the emission of deleterious species or outgassing.
- the wholly solid-state lithium- based systems of preferced embodiments of the present invention use less lithium in the cell than is typically used in existing lithium cells, thereby reducing cost as well as increasing the energy content.
- Fig. 1A shows a metallized plain polymer film with an unmetallized margin and a coating of active cathode material not on the margin.
- Fig. IB also shows a metallized plain polymer film with an unmetallized margin and layers of active anode material and solid polymer electrolyte not on the margin.
- Fig. IC shows an alternative embodiment of an electrode structure for a battery.
- Fig. 2 shows the combined cathode, anode and electrolyte components of Figs. 1 A and 1
- Fig. 3 shows the layers of a thin lithium polymer electrolyte bipolar battery cell.
- Fig. 4 illustrates a wound electrochemical cell for an ultra-thin battery employing layers similar to those of Figs. 1 A and IB.
- a very thin, low resistance, flexible film of polymer electrolyte preferably is prepared as disclosed in related application U.S. Pat. App. No. 09/388,471, filed September 2, 1999, or as described and exemplified below:
- EXAMPLE 1 A base polymer material and a lithium salt are dissolved in a suitable liquid organic solvent (anhydrous) to form a polymer solution.
- the lithium salt is lithium hexafluorophosphate (LiPF 6 ), lithium perchlorate (LiClO 4 ), lithium tetrafluoroborate (LiBF 4 ), lithium hexafluoroarsenate (LiAsF 6 ), lithium tetrachloroaluminate (LiAlCl ), lithium trifluoromethanesulfonate (LiCF 3 SO ), lithium methide (LiC(SO 2 CF 3 ) 3 or lithium bis(trifluoromethane sulfonyl) imide (LiN(CF 3 SO 2 ) 2 ).
- LiPF 6 lithium hexafluorophosphate
- LiClO 4 lithium perchlorate
- LiBF 4 lithium tetrafluoroborate
- LiAsF 6 lithium hexafluoroarsenate
- LiAlCl lithium tetrachloroaluminate
- LiCF 3 SO lithium trifluoromethane
- the base polymer material contains at least two polymers, the first being an ionically conductive polymer, the monomers of which have a hetero atom with a lone pair of electrons available for the metal ions of a metal salt to attach to and move between during conduction, when the polymer is mixed with the lithium salt.
- the second polymer is more inert with respect to ionic conductivity and is stronger than the first polymer when they are in the form of a thin film. The conductivity is measured when each of the polymers is in the form of a thin film.
- the second polymer is polyester (PET), polypropylene (PP), polyethylene napthlate (PEN), polyvinylidene fluoride (PVDF), polycarbonate (PC), polyphenylene sulfide (PPS), polytetrafluoroethylene (PTFE), or another polymer that possess stability and strength characteristics similar to one of these polymers.
- the second polymer serves to provide the basic backbone or strength of the final polymer electrolyte when manufactured in ultra-thin films.
- the first polymer material provides sufficient strength to the polymer electrolyte, one need not include a second polymer in the composition of the base polymer material.
- a very high surface area inorganic filler - either fumed silica or alumina having an average particle size ⁇ 0.05 micron and a surface area of at least about 100 m 2 /g - is then extensively dispersed with a concentration in a range from about 0.1-60% by volume of the final solid polymer composition to enhance the mechanical stability and ionic conductivity of the thin film into which the polymer material with inorganic filler is cast. Further to this polymer mixture is added a finely dispersed ion conducting material having an average particle size ⁇ 0.1 micron and initial ionic conductivity of at least 2 x 10 "3 S/cm at room temperature.
- the ion conducting material is a lithium ion conductor and makes up 0.1-80%) by volume of the final composition or composite.
- the lithium ion conductor is preferably a lithium ion conducting sulfide glass or a ceramic lithium ion conductor such as lithium beta alumina or a silicate, or some other ionically conducting material of high lithium ion mobility. Care is taken to blend these constituents in an inert atmosphere since the sulfide glasses are extremely hygroscopic and may effect the performance of the final lithium batteries.
- the base polymer material with the salt, inorganic filler, and glassy or ceramic lithium ion conductor may be intimately mixed with one another and may be cast or extruded using a hot-melt resin process. Dispersion of the inorganic filler and glassy or ceramic ion conductor into the polymer blend is performed during polymer and salt dissolution into the solvent or during extrusion of the polymer.
- the filler is preferably 0.1-20% fumed silica or alumina having an average particle size less than or equal to 0.01 micron and the glassy or ceramic lithium ion conductor is also preferably 0.1-20% by volume having an average particle size less than or equal to 0.01 micron.
- LiClO 4 salt 2 g was mixed with 4 g of PEO (MW 3 x 10 5 ) and 4 g of PEG (MW 5 x IO 6 ) in a less than 1% relative humidity dry room.
- the polymer/salt mixture was cast on an aluminum plate.
- the material was a solid gel and its ionic conductivity measured 5 x IO "5
- the ionic conductivity of another similarly-prepared polymer/salt mixture measured 7 x 10 " S/cm. Knowing the base ionic conductivity of the initial polymer/salt mixture, 2 g of high surface area alumina and 5 g of finely powdered LiI-Li S-B S glass was added to the polymer/salt solution, and the final mixture was cast on an aluminum plate. The conductivity
- EXAMPLE 3 2 g of lithium imide salt was mixed with a range of acrylate monomers and oligomers, including 2.1 g of isobornyl acrylate, 0.3 g of 1,6-hexanediol diacrylate, 0.8 g trimethylolpropane triacrylate, 8 g ebecryl 230 and 4 g PEO, and 0.014 g of ITX and 0.14 g of Irgacure 184 photo initiator, dispersed in 20 volume percent isopropanol. A sample portion of this mixture was cast in a thin sheet, the IPA evaporated completely and cured using a 1000 Watts UV light.
- acrylate monomers and oligomers including 2.1 g of isobornyl acrylate, 0.3 g of 1,6-hexanediol diacrylate, 0.8 g trimethylolpropane triacrylate, 8 g ebecryl 230 and 4 g PEO, and 0.014
- a polymer electrolyte formulated as described above can be prepared in very thin form without loss of mechanical integrity, conductivity, and mechanical strength.
- the above-described preferred methods which produce excellent ionic conductivity and mechanical strength of the base polymer via the two polymer hybrid design and addition of high surface area alumina or silica, and improving the ionic conductivity of the polymer electrolyte by introducing plasticizer salts and ionically conductive glassy constituents into the base polymer, as thin as 1 micron or less can be manufactured simply by selective use of the various components of the polymer electrolyte.
- Such polymer electrolytes are not only thin, but also truly flexible; and the thinness of the structure allows the possibility of lower resistances than are available from liquid electrolytes absorbed in traditional polypropylene separators.
- Traditional separator materials are usually at least 25 microns thick, and the conductivity of the solvent electrolyte is usually about IO "3 to IO "2 S/cm at room temperature.
- the advantageous design of the new solid polymer electrolytes makes possible thinner polymer electrolyte sections with effective resistance at least one-half of that observed in liquid electrolytes alone.
- a liquid electrolyte with an ionic conductivity of 5 x 10 "3 S/cm absorbed in a 25 micron polypropylene separator has an effective resistance of about 0.5 ohm
- a 1 micron polymer electrolyte fabricated according to one of the methods of the invention, with an ionic conductivity of 5 x 10 " S/cm has an effective resistance of only about 0.2 ohm.
- the thinness of the polymer electrolyte allows the film to be highly flexible.
- compositions and devices similar to these and based on sodium, potassium, magnesium, calcium, zinc, nickel, carbon, ion-insertion polymers, ion-insertion inorganic electrodes or tin oxide anode materials, and compatible metal salts would also be satisfactory.
- each polymer substrate electrode material has different, easily identifiable, characteristics and thermal and mechanical properties, and each behaves differently depending upon its use.
- a suitable material can be readily selected based on the desired properties.
- the thickness of the metal coating should be kept as thin as possible, while concurrently ensuring that its conductivity is very high.
- the coating thickness has a conductivity of less than about 1.0 ohm per square, preferably less than 0.1 ohm per square, and more preferably about 0.01 ohm per square. This will ensure low resistance loss during current drain from the metallized substrate.
- the metallization may be present on only one side of the polymer layer or substrate, but is preferably provided on both sides thereof.
- the metallization preferably is accomplished to leave an unmetallized (non-metallized) margin having a width in a range from about one millimeter (mm) to about three mm.
- the non- metallization margin is provided at opposite sides of the polymer material, but on the same edge.
- the coating material will be applied to the metallized portion and not the margin.
- the thin metal or metallized polymer substrate described above is coated with very thin film active anode and cathode material to complete an electrode structure that is thinner than known electrodes for thin polymer electrolyte electrochemical devices.
- Conventional calendaring of the anode and cathode from paste will not lead to the desired thickness.
- the active anode or cathode material is milled extensively in a solvent to reduce the particle size, and then injected directly onto the substrate and subsequently drawn into thin films of any of a variety of predetermined thicknesses.
- the finely divided electrode material is blended with the polymer electrolyte solution.
- Example 4 The polymer electrolyte solution of Example 4 was mixed with 20 g of V 6 Oi 3 cathode active material and 0.7 g of acetylene black, and an additional 20 mis of acetonitrile, and the mixture milled for two days using zirconia grinding media.
- the cathode was cast directly onto aluminum sheets in thin film form (20 microns), the solvent evaporated and the dried cathode/polymer mix cured using electron beam radiation.
- a number of different methods may be employed to cast or coat the active electrode material/polymer electrolyte composite from a solvent-based system.
- Some suitable methods include knife coaters, doctor blade coaters, screen-printing, wire-wound bar coaters or Mayer rods, air knife (or air doctor) coaters, squeeze roll or kiss coaters, gravure coaters, reverse roll coaters, cast film coaters, and transfer roll coaters.
- One coating system may be preferred over another to achieve a particular intended final result. For instance, coaters that apply an excess to the substrate web and remove the surplus coating, leaving a desired amount on the surface of the web are usually knife coaters, doctor blade coaters, bar or rod coaters, air knife coaters, and squeeze roll coaters.
- Coaters that apply a predetermined amount of coating to the web include reverse roll coaters, gravure coaters, and transfer roll coaters. Any of these methods could be suitable for coating dry polymer electrolyte film thickness in the range of about 2 to 100 microns.
- One preferred technique for applying an electrode/polymer electrolyte composite material is to inject the electrode slurry with the finely dispersed inorganic and organic constituents directly onto the substrate, and then draw it out into a thin film of the desired thickness using wire wound rods (Mayer rods) with different wire diameters.
- the different diameter wire controls the wet slurry thickness.
- This method, and the other electrode deposition techniques described herein have not been used previously in the battery industry to manufacture electrodes. These methods greatly facilitate obtaining an electrode material/polymer electrolyte composite film that is extremely uniform, pin-hole free, flexible and ultra-thin. Dry film thickness of 2 microns to more than 100 microns can be controlled using this process.
- An alternative coating method includes incorporating each of the active electrode composites mixtures into its own aerosol mix and spraying an atomized aerosol of each material directly onto the respective opposite sides of the film substrate. This can be done rapidly while moving the substrate past the points of aerosol spray at high speed.
- the sprayed active electrolyte materials are cured either by drying or radiation, if the material contains radiation curable materials.
- Another alternative way of coating the substrate with active electrode material is to evaporate the respective electrode materials directly onto respective opposite sides of the substrate.
- the polymer electrolyte blend include a liquid radiation curable polymer capable of dissolving the metal salt and dispersing the inorganic materials. It is also preferred if inclusion of organic solvent in the electrolyte mixture can be avoided.
- Polymer electrolytes and active electrode/polymer electrolyte composites manufactured in this manner can result in final film thickness of less than 1 micron and more preferably in thickness of about 0.2 microns or less.
- a preferred dual electrode structure 25 for a thin film lithium polymer electrolyte battery is fabricated by laminating anode 60 and cathode 20 elements on respective opposite sides of a double- metallized polymer substrate 13 to yield a highly flexible and strong electrode structure for the battery, as illustrated in Fig. IC.
- Double-metallized polymer substrate 13 comprises polymer substrate 12 and metallization layers 16a and 16b.
- each of the anode 60 and cathode 20 elements are provided on each of the anode 60 and cathode 20 elements on the opposite sides of the metallized polymer substrate.
- Metal is sprayed on opposite ends of the laminated metallized polymer substrate for the battery terminations, similar to the manner of termination shown in Fig. 2.
- Employing double-metallized substrates instead of singly- metallized electrode substrates further reduces the final thickness of the electrode structures, providing a ratio of substrate thickness to active electrode thickness less than about 0.5, and surface resistivity for each anode and cathode elements of less than 0.1 ohms per square. It can be readily appreciated that for metallic anode or cathode elements, the surface resistivity will be significantly lower.
- anode and cathode composite materials have been coated or laminated onto either an ultra-thin metallic or a metallized plastic current collector, as described above, the anode and cathode elements are coated directly by a thin solid polymer electrolyte.
- solid polymer electrolyte layer 70 is shown overlying anode 60.
- Application of the solid polymer electrolyte is preferably accomplished in a single-step operation using any of the various methods of depositing the electrolytes as described in related patent application no. 09/388,741, including casting, hot-melt extrusion, hot-melt pressing, and spraying.
- Still another alternative electrode structure employing a polymer substrate is the thin film bipolar element.
- a bipolar structure is fabricated by laminating anode and cathode active elements on respective opposite sides of a double-metallized substrate of the same polymer material as described in the previous section entitled "Metalized Polymer Substrates" and illustrated in Fig. IC.
- the polymer substrate is impregnated with an electronically conductive material such as carbon black or metallic elements, which are inert to the active electrode, as in the bipolar unit shown in Fig. 3.
- the electronically conductive material is dispersed throughout the polymeric material of the substrate.
- the electrode layers are 0.1-100 microns.
- the composite active cathode or anode is preferably screen-printed onto the substrate element, but one of the above-described techniques for applying active electrode composite could also be used.
- a strong and yet flexible half-element anode consisting of a layer of anode element is made by depositing the anode material onto a very thin metallized plastic or metallic curcent collector.
- this anode half-element is lithium metal that is preferably deposited via evaporation or sputtering technique directly onto an aluminum or nickel metallized plastic substrate or directly onto the metallic cunent collector (also Al or Ni) in a continuous step.
- Desired thickness of the plastic substrate is 0.5 to 50 microns while the desired resistivity of the metallization layer is less than 0.1 ohms per square, and the desired thickness of the lithium deposit is between 0.1 microns to 100 microns, and preferably between 0.1-10 microns.
- Lithium anodes manufactured in this manner are ultra-thin, flexible, easily handled, non-distortable, stronger and relatively inexpensive. Also, the precise capacity per unit area can be fabricated into the lithium anode composition for use in a lithium polymer electrolyte battery designed for a specific use requiring a defined battery capacity, a feature not possible with lithium metal foil anodes. This strong metallized polymer strip permits winding of the cell components in such a way that no distortion or damage to the lithium electrode occurs. Tabbing the lithium using metal punching through the polymer material allows greater strength than if thin film lithium is to be used alone.
- the polymer material provides strength during the tabbing and winding process as well as giving some backbone during the plating and stripping operation of the lithium during charge and discharge.
- a variety of ultra-thin solid state lithium polymer electrolyte electrochemical cells may be fabricated using the very thin solid polymer electrolytes described elsewhere herein and in U.S. Pat. App. No. 09/388,741, in combination with very thin electrode elements. Due to their flexibility and thinness, some of the more preferred electrochemical cells have conformable structures. Fabrication of a simple electrochemical cell includes laminating an anode half cell with a cathode half cell and placing a layer of solid polymer electrolyte having an initial conductivity of at least 10 "3 to IO "4 S/cm between the half cells, as shown in Fig. 2. The cell may employ the thinnest possible inactive battery components with a solid polymer electrolyte.
- both sides of an ultra-thin plastic or polymer substrate are laminated with the anode and cathode elements so as to yield a preferred ultra-thin, highly flexible electrode, as shown in Fig. 3.
- multiple layers may be wound together as shown in Fig. 4.
- Polymer electrolytes fabricated in very thin film form are tightly rolled with thin film anode and cathode electrodes. It is preferred that once the individual thin film cell components have been laminated, the finished cell is heated to about 60-80°C for about 2 hours. This enhances the electrode/electrolyte interface and allows better interfacial adhesion and improved cyclability.
- a battery By designing an all-solid-state battery based on very thin film active and inactive components, one can effectively increase the surface area of the active plates. As a consequence, a battery will have a higher current drain capability, low resistance, higher energy content, low self-discharge, a wide operating temperature range, freedom from dendrite formation, higher efficiency, higher capacity utilization, higher cycle life, and better reliability and safety. Since there is less chance of lithium dendrite formation with the new solid polymer electrolytes, very thin polymer electrolyte membranes (e.g. l-10 ⁇ ) as the separator and ionic carrier are feasible. Such a battery is also able to tolerate overcharge, without emission of any deleterious species or outgassing.
- very thin polymer electrolyte membranes e.g. l-10 ⁇
- An especially desirable thin film lithium polymer electrolyte rechargeable battery includes an ultra thin film metallized polymer substrate about 0.5-50 microns thick. This substrate is used in conjunction with very thin film electrode and solid polymer electrolyte structures having thicknesses less than 0.5 microns.
- the thickness of the metallization layer on the polymer layer of the substrate is selected according to the predetermined desired conductivity of the metallization layer.
- the metallization layer ranges up to about 1 micron. For many applications the preferred thickness is about 0.01 micron or less.
- the cathode from Example 5 was used to make a lithium bipolar battery. 10 x 10 cm sheets of the cathode were cut, a thin layer (10 microns) of the polymer electrolyte from Example 4 was cast directly onto the cathode, the solvent completely evaporated and the cathode/pre-cured polymer electrolyte cured using UV light. The cathode/polymer electrolyte was then laminated on the back side with 1 mil thick lithium metal foil of the same area to make a bipolar plate. Two bipolar plates constructed in the above manner and two half plates of lithium and cathode were then laminated together to form a 10 V bipolar battery.
- the recycling of these batteries is expected to be relatively simpler than the recycling of lithium ion batteries - a major environmental benefit, especially when these batteries find use in portable electronics, telecommunications and mass electric transportation. It is also expected that the new battery technology, after more extensive testing, will prove itself to be safer than earlier technology batteries containing liquid organic solvents.
- the polymer battery may contain lithium metal which is flammable, the fact that there are no liquid organic solvents in the battery to propagate the flammability of lithium metal and also the lithium is laminated tightly with the metallized polymer and other components of the battery will tend to limit flammability of the lithium metal. With no toxic compounds in the chemistry and no conosive liquids in the battery (e.g.
- An even thinner rechargeable solid polymer electrolyte battery can be fabricated with an anode half cell, a cathode half cell and at least one bipolar plate disposed therebetween.
- a bipolar battery has a common current collector for both the anode and the cathode and eliminates the use of one of the current collectors from each cell.
- a lithium or cathode half cell may include a layer of the new polymer electrolyte composition with an initial ionic conductivity of at least 10 "3 to IO "4 S/cm and containing at least one ionically conductive component base polymer material, a lithium salt, a high surface area inorganic filler such as alumina with an average particle size less than 0.05 microns and a surface area of at least 100 m 2 /g dispersed in the polymer electrolyte, and a lithium ion glassy conductor having an average particle size of less than 0.1 micron also dispersed into the polymer electrolyte.
- Each bipolar unit also contains on one side a layer of ultra-thin polymer electrolyte as described above.
- bipolar half-elements are best fabricated in rectangular units using spray deposition or screen-printing methods to form the electrode coatings as well as electrolyte coatings. This kind of design is also readily adaptable for an all-solid-state design, especially a flexible polymer electrolyte battery.
- Batteries can be stacked in rectangular prismatic modules or the stacks can be jelly-rolled to form a cylindrical battery of higher voltage than the individual cell voltage, as described in more detail in the following section.
- An ultra-thin battery assembly may be modified, if desired, by laminating the components into rolled or cylindrical geometries, or in a zig-zag or concertina configuration.
- the cylindrical geometry may be flattened after winding to form an oval shape, or flat-rectangular coupons could simply be laminated to form flat cells.
- Three principal webs comprising anode 310, solid polymer electrolyte film 311 and cathode 312 are rolled or wound as illustrated in Fig. 4, to form lithium polymer electrolyte battery 315.
- the layers may be tightly stacked or laminated together.
- a tightly wound construction is prefened, in part because winding removes air from between the layers, and enhances creation and maintenance of continuous contact between the layers. The exercise of care in winding is essential to avoid electrical shorting of the beginning of the turns. This may be facilitated by staggering or offsetting the beginning of each layer.
- the conducting metallized layer deposited on the plastic film 326 may be too thin to be directly bonded to for termination purposes, so the rolled up laminate, resembling a "battery/capacitor hybrid," is taped at the edge 316, and may then be strapped in a tray (not shown) that is open on both sides. This provides access to both ends 317 and 318 of the battery 315 for schooping or, preferably, metal spraying of the roll ends, first with a high zinc content solder (harder material) followed by a regular softer "Babbitt" end spray solder (90% tin: 10% zinc). The first end spray scratches the metallized surface and creates a trough to build a better electrical and mechanical contact.
- the tight winding and offset spacing of individual layers prevents the zinc from penetrating to the active components.
- This combination of end sprays also allows better contact adhesion with the final termination.
- the end spray also connects all the thin layers together, resulting in a continuous contact along the entire length of the film, in contrast to a cylindrical battery where only one lead contact is made at one end of the electrode.
- the first end spray coat (harder material) is employed in order to enhance heat transition during the schooping, to reduce shrinkage of the polymer and to increase the heat capacity on the metallized layer by providing a "heavy edge" which reinforces the metallization at the contact area.
- aluminum leads (not shown) are soldered onto each of the ends 317 and 318 to form the final termination.
- the battery may then be packaged in a plastic case filled with epoxy, or conformally coated to maintain pressure on the cell, as well as to provide a hermetic seal to further protect it from humidity.
- This rolled laminate or battery-capacitor hybrid 315 is heated to about 80° C for a period of from 2 to 5 minutes, to improve the interface. If desired, it may be heated under vacuum before epoxying, to improve the contact between layers even further.
- the anode and cathode elements are preferably laminated on both sides of a double- metallized polymer substrate material so as to yield a highly flexible electrode.
- a carbon anode is calendared on both sides of a copper current collector.
- the lithium anode material 322 is laminated or coated in a very thin film on both sides of copper metallized polymer (e.g., PET) material 323 so that no distortion or damage to the lithium anode electrode will occur during the winding operation of the cell components.
- the electrode material be evaporated directly onto the metallized polymer.
- a similar structure (apart from the specific materials employed, e.g., aluminum rather than copper for the metallization) may exist for the cathode.
- An insulator sheet 325 and a metallized PET current collector 326 complete the assembly prior to winding.
- the use of metallized plastic substrates in thickness of less than 1 micron reduces the inactive components of the cell significantly, compared to state-of-the-art lithium ion polymer electrolyte battery substrate material, thereby increasing the energy density of the battery even further.
- the ratio of substrate thickness to electrode thickness is about 0.8 to 1.
- reduction of the ratio of substrate thickness to electrode thickness to less than 0.5, in combination with reduced electrolyte thickness and reduced dead space at the top and bottom of the jelly roll structure significantly improves the battery's energy density, rate capability, reliability, cycle life, and safety over prior art batteries.
- a high-speed manufacturing process for making an ultra-thin, flexible, laminar battery includes winding a cathode sheet, such as that described in Example 5 into a roll and then extruding, spraying, screen-printing, or evaporating a uniform thin layer of a solid polymer electrolyte composition described above onto the cathode sheet while the cathode roll is drawn at a uniform rate by an uptake reel.
- the current collector may be ultra-thin metal instead of metallized plastic.
- the cathode composite sheet have nanow margins along both longitudinal edges where the plastic substrate material is uncoated by the active cathode material and the polymer electrolyte, in order to facilitate battery completion.
- the polymer electrolyte composition is cured as the composite is continuously wound by an uptake reel, to yield a roll of cathode composite.
- a roll of flexible lithium anode sheet which is preferably lithium deposited on aluminum or nickel metallized polyester, is wound onto a reel.
- a uniform thin layer of the solid polymer electrolyte composition may be applied to the lithium layer similar to the manner of coating the cathode.
- a mixture of pre-cured polymer, lithium salt, filler and ionic conductor is sprayed directly onto either the anode or cathode material traveling at high speed from one roll to another. Electron beam radiation is then applied to cure the in situ deposited polymer electrolyte.
- the pre-cured polymer electrolyte mixture atomizer is preferably adjustable to various settings in order to control the exact thickness of the deposit.
- solid polymer electrolyte thickness of less than 0.2 microns can be achieved.
- Another alternative way of depositing the electrolyte coating on an electrode is to cast the electrolyte composition from a solvent based mixture and then evaporate or recover the solvent for recycling, leaving behind a thin layer of the polymer electrolyte.
- the two sheets are placed close together and laminated together so that the adjacent layers (i.e. flexible cathode substrate/cathode/electrolyte/lithium/flexible anode substrate are in continuous mutual contact and extraneous air is excluded from the resulting laminated cell.
- Another alternative way is to form the polymer electrolyte separately either through extrusion or casting, and wind the anode/polymer electrolyte/cathode in a roll-to-roll laminate form.
- the laminated cell may be heated under conditions of low atmospheric pressure (vacuum).
- Electrode and electrolyte materials having the above-described compositions can be manufactured in thickness of 1 micron, or even less, using an extrusion process.
- active electrode electrolyte layers can be made as thin as 0.2 micron.
- the polymer electrolytes and electrodes disclosed herein will be mass produced at speeds of 500 meters per minute and in thickness of 0.2 to 100 microns for producing thin film rechargeable lithium polymer electrolyte batteries.
- a similar high-speed production process, using a continuous roll-to-roll winding of the various battery elements in the form of strong, thin sheets will reduce the cost of manufacturing laminar solid polymer electrolyte batteries significantly.
- Another important advantage of this high-speed method of production is that batteries are produced which contain more uniformly thick, pin-hole free electrolyte layers than is possible with conventionally produced polymer electrolyte batteries.
Abstract
Description
Claims
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Also Published As
Publication number | Publication date |
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TW521450B (en) | 2003-02-21 |
AU7063800A (en) | 2001-03-26 |
MY126958A (en) | 2006-11-30 |
US6664006B1 (en) | 2003-12-16 |
CA2382127A1 (en) | 2001-03-08 |
JP2003508887A (en) | 2003-03-04 |
WO2001017052A3 (en) | 2002-02-21 |
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