U.S. patent application number 11/400781 was filed with the patent office on 2007-09-27 for rechargeable lithium/water, lithium/air batteries.
This patent application is currently assigned to Sion Power Corporation. Invention is credited to John D. Affinito, Yordan M. Geronov, Yuriy V. Mikhaylik, Christopher J. Sheehan.
Application Number | 20070221265 11/400781 |
Document ID | / |
Family ID | 40711684 |
Filed Date | 2007-09-27 |
United States Patent
Application |
20070221265 |
Kind Code |
A1 |
Affinito; John D. ; et
al. |
September 27, 2007 |
Rechargeable lithium/water, lithium/air batteries
Abstract
Electrochemical cells, and more specifically, rechargeable
batteries comprising lithium anodes for use in water and/or air
environments, as well as non-aqueous and non-air environments, are
presented. In one embodiment, an electrochemical cell includes an
anode comprising lithium and a multi-layered structure positioned
between the anode and an electrolyte of the cell. A multi-layered
structure can include at least a first single-ion conductive
material layer (e.g., a lithiated metal layer), and at least a
first polymeric layer positioned between the anode and the
single-ion conductive material. The invention also can provide an
electrode stabilization layer positioned within the electrode,
i.e., between one portion and another portion of an electrode, to
control depletion and re-plating of electrode material upon charge
and discharge of a battery. Advantageously, electrochemical cells
comprising combinations of structures described herein are not only
compatible with environments that are typically unsuitable for
lithium, but the cells may be also capable of displaying long cycle
life, high lithium cycling efficiency, and high energy density.
Inventors: |
Affinito; John D.; (Tucson,
AZ) ; Mikhaylik; Yuriy V.; (Tucson, AZ) ;
Geronov; Yordan M.; (Tucson, AZ) ; Sheehan;
Christopher J.; (Santa Fe, NM) |
Correspondence
Address: |
WOLF GREENFIELD & SACKS, P.C.
600 ATLANTIC AVENUE
BOSTON
MA
02210-2206
US
|
Assignee: |
Sion Power Corporation
Tucson
AZ
|
Family ID: |
40711684 |
Appl. No.: |
11/400781 |
Filed: |
April 6, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60785768 |
Mar 22, 2006 |
|
|
|
Current U.S.
Class: |
136/243 ;
136/253 |
Current CPC
Class: |
Y02E 60/10 20130101;
H01M 4/62 20130101; H01M 4/02 20130101; H01M 4/385 20130101; H01M
4/66 20130101; H01M 4/366 20130101; H01M 10/4235 20130101; Y02P
70/50 20151101; H01M 50/46 20210101; H01M 4/13 20130101; H01M 4/661
20130101; H01M 4/382 20130101; H01M 10/36 20130101; H01M 2300/0002
20130101; H01M 2004/021 20130101; H01M 4/628 20130101; H01M 10/44
20130101; H01M 2004/027 20130101 |
Class at
Publication: |
136/243 ;
136/253 |
International
Class: |
H02N 6/00 20060101
H02N006/00; H01L 25/00 20060101 H01L025/00 |
Claims
1. An electrochemical cell comprising: an anode comprising a base
electrode material comprising lithium; a single-ion conductive
material; a polymeric layer between the base electrode material and
the single-ion-conductive material; and a separation layer between
the base electrode material and the polymeric layer.
2. An electrochemical cell as in claim 1, further comprising an
aqueous-based electrolyte in electrochemical communication with the
anode.
3. An electrochemical cell as in claim 1 comprising, on the anode,
a multi-layered protective structure comprising a plurality of
single-ion conductive material layers, each single-ion conductive
material layer having a thickness of no greater than 10 microns,
and a plurality of polymer layers, each single-ion conductive
material layer having a thickness of no greater than 10 microns,
the polymer layers interspersed between the single-ion conductive
material layers.
4. An electrochemical cell as in claim 3, wherein at least a
portion of the ion-conductive material of the multi-layered
structure contains voids at least partially filled with an
auxiliary transport-inhibiting substance.
5. An electrochemical cell as in claim 3, wherein at least one of
the plurality of single-ion conductive material layers comprises a
metal layer.
6. An electrochemical cell as in claim 3, wherein each of the
plurality of single-ion conductive material layers comprises a
metal layer.
7. An electrochemical cell as in claim 1, wherein the separation
layer is a plasma treated layer.
8. An electrochemical cell as in claim 1, wherein the anode
comprises: a first layer comprising lithium; an embedded single-ion
conductive, non-electronically conductive layer on the first layer;
a second layer comprising lithium on the embedded layer, wherein
the second layer is positioned between the first layer and the
electrolyte.
9. An electrochemical cell as in claim 8, further comprising a
current collector in electronic communication with both the first
layer and the second layer.
10. An electrochemical cell as in claim 9, wherein the first and
second layers define a layered structure with at least one edge,
and the current collector is in contact with the edge of the anode
across both the first and second layers.
11. An electrochemical cell comprising: an anode comprising a base
electrode material comprising lithium; a multi-layered structure
positioned between the anode and an electrolyte of the cell, the
multi-layered structure comprising: at least two first layers each
of a single-ion conductive material; at least two second layers
each of a polymeric material; wherein the at least two first layers
and at least two second layers are arranged in alternating order
with respect to each other, and wherein each layer of the
multi-layered structure has a maximum thickness of 25 microns.
12. An electrochemical cell as in claim 11, wherein the
multi-layered structure includes at least three layers each of the
single-ion conductive material and at least three second layers
each of the polymeric material, arranged in alternating order with
respect to each other.
13. An electrochemical cell as in claim 1 1, wherein the
multi-layered structure includes at least four layers each of the
single-ion conductive material and at least four second layers each
of the polymeric material, arranged in alternating order with
respect to each other.
14. An electrochemical cell as in claim 11, wherein the
multi-layered structure includes at least five layers each of the
single-ion conductive material and at least five second layers each
of the polymeric material, arranged in alternating order with
respect to each other.
15. An electrochemical cell as in claim 11, wherein the
multi-layered structure includes at least six layers each of the
single-ion conductive material and at least six second layers each
of the polymeric material, arranged in alternating order with
respect to each other.
16. An electrochemical cell as in claim 11, wherein the
multi-layered structure includes at least seven layers each of the
single-ion conductive material and at least seven second layers
each of the polymeric material, arranged in alternating order with
respect to each other.
17. An electrochemical cell as in claim 11, wherein the
multi-layered structure has a maximum overall thickness of 300
microns.
18. An electrochemical cell as in claim 11, wherein the
multi-layered structure has a maximum overall thickness of 250
microns.
19. An electrochemical cell as in claim 11, wherein the
multi-layered structure has a maximum overall thickness of 200
microns.
20. An electrochemical cell as in claim 11, wherein the
multi-layered structure has a maximum overall thickness of 150
microns.
21. An electrochemical cell as in claim 11, wherein the
multi-layered structure has a maximum overall thickness of 100
microns.
22. An electrochemical cell as in claim 11, wherein the
multi-layered structure has a maximum overall thickness of 75
microns.
23. An electrochemical cell as in claim 11, wherein the
multi-layered structure has a maximum overall thickness of 50
microns.
24. An electrochemical cell as in claim 11, wherein at least a
portion of the ion-conductive material of the multi-layered
structure contains voids at least partially filled with an
auxiliary transport-inhibiting substance.
25. An electrochemical cell as in claim 11, wherein each layer of
the multi-layered structure has a maximum thickness of 10
microns.
26. A method of electrical energy storage and use, comprising:
providing an electrochemical cell comprising an anode with lithium
as the active anode material, a cathode, and an aqueous electrolyte
in electrochemical communication with the anode and cathode;
cycling the cell, by alternatively discharging and charging the
cell, at least three times wherein, at the end of the 3.sup.rd
cycle, the cell exhibits at least 80% of the cell's initial
capacity.
27. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
five times wherein, at the end of the 5.sup.th cycle, the cell
exhibits at least 80% of the cell's initial capacity.
28. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
ten times wherein, at the end of the 10.sup.th cycle, the cell
exhibits at least 80% of the cell's initial capacity.
29. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
fifteen times wherein, at the end of the 15.sup.th cycle, the cell
exhibits at least 80% of the cell's initial capacity.
30. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
twenty-five times wherein, at the end of the 25.sup.th cycle, the
cell exhibits at least 80% of the cell's initial capacity.
31. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
fifty times wherein, at the end of the 50.sup.th cycle, the cell
exhibits at least 80% of the cell's initial capacity.
32. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
seventy-five times wherein, at the end of the 75.sup.th cycle, the
cell exhibits at least 80% of the cell's initial capacity.
33. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
one hundred times wherein, at the end of the 100.sup.th cycle, the
cell exhibits at least 80% of the cell's initial capacity.
34. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
one hundred fifty times wherein, at the end of the 150.sup.th
cycle, the cell exhibits at least 80% of the cell's initial
capacity.
35. A method as in claim 26, the method comprising: cycling the
cell, by alternatively discharging and charging the cell, at least
two hundred fifty times wherein, at the end of the 250.sup.th
cycle, the cell exhibits at least 80% of the cell's initial
capacity.
36. An electrochemical cell comprising: an anode comprising a base
electrode material comprising lithium; a single-ion conductive
material; a polymeric layer between the base electrode material and
the single-ion-conductive material; a separation layer between the
base electrode material and the polymeric layer; and an
aqueous-based electrolyte in electrochemical communication with the
anode.
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Application entitled,
"Lithium/Water, Lithium/Air Batteries," filed on Mar. 22, 2006.
FIELD OF INVENTION
[0002] The present invention relates to rechargeable
electrochemical cells, and more specifically, to electrochemical
cells comprising lithium anodes for use in water and/or air
environments.
BACKGROUND
[0003] There has been considerable interest in recent years in
developing high energy density batteries with lithium containing
anodes. Lithium metal is particularly attractive as the anode of
electrochemical cells because of its extremely light weight and
high energy density, compared for example to anodes, such as
lithium intercalated carbon anodes, where the presence of
non-electroactive materials increases weight and volume of the
anode, and thereby reduces the energy density of the cells, and to
other electrochemical systems with, for example, nickel or cadmium
electrodes. Lithium metal anodes, or those comprising mainly
lithium metal, provide an opportunity to construct cells which are
lighter in weight, and which have a higher energy density than
cells such as lithium-ion, nickel metal hydride or nickel-cadmium
cells. These features are highly desirable for batteries for
portable electronic devices such as cellular phones and laptop
computers where a premium is paid for low weight. Unfortunately,
the reactivity of lithium and the associated cycle life, dendrite
formation, electrolyte compatibility, fabrication and safety
problems have hindered the commercialization of lithium cells.
[0004] Lithium battery systems generally include a cathode which is
electrochemically lithiated during the discharge. In this process,
lithium metal is converted to lithium ion and transported through
electrolyte to the battery's cathode where it is reduced. In a
lithium/sulfur battery, lithium ion forms one of a variety of
lithium sulfur compounds, at the cathode. Upon charging, the
process is reversed, and lithium metal is plated, from lithium ion
in the electrolyte, at the anode. In each discharge cycle, a
significant number (e.g., 15-30%) of available Li may be
electrochemically dissolved in the electrolyte, and nearly this
amount can be re-plated at the anode upon charge. Typically,
slightly less lithium is re-plated at the anode at each charge, as
compared to the amount removed during each discharge; a small
fraction of the metallic Li anode typically is lost to insoluble
electrochemically inactive species during each charge-discharge
cycle.
[0005] This process is stressful to the anode in many ways, and can
lead to premature depletion of Li and reduction of the battery
cycle life. During this cycling, the Li anode surface can become
roughened (which can increase the rate of field-driven corrosion)
and Li surface roughening can increase proportionally to the
current density. Many of the inactive reaction products associated
with overall Li loss from the anode upon cycling can also
accumulate on the increasingly roughened Li surface and may
interfere with charge transport to the underlying metallic Li
anode. In the absence of other degradation processes in other parts
of the battery, the per-cycle Li anode loss alone can eventually
render the cell inactive. Accordingly, it is desirable to minimize
or inhibit Li-loss reactions, minimize the Li surface
roughness/corrosion rate, and prevent any inactive corrosion
reaction products from interfering with charge transport across the
Li anode surface. Especially at higher current density (which is
commercially desirable) these processes can lead to quicker cell
death.
[0006] The separation of a lithium anode from the electrolyte of a
rechargeable lithium battery or other electrochemical cell can be
desirable for a variety of reasons, including the prevention of
dendrite formation during recharging, reaction of lithium with the
electrolyte, and cycle life. For example, reaction of a lithium
anode with the electrolyte may result in the formation of resistive
film barriers on the anode, which can increase the internal
resistance of the battery and lower the amount of current capable
of being supplied by the battery at the rated voltage. Many
different solutions have been proposed for the protection of
lithium anodes in such devices, including coating the lithium anode
with interfacial or protective layers formed from polymers,
ceramics, or glasses, the important characteristic of such
interfacial or protective layers being to conduct lithium ions. For
example, U.S. Pat. Nos. 5,460,905 and 5,462,566 to Skotheim
describe a film of an n-doped conjugated polymer interposed between
the alkali metal anode and the electrolyte. U.S. Pat. No. 5,648,187
to Skotheim and U.S. Pat. No. 5,961,672 to Skotheim et al. describe
an electrically conducting crosslinked polymer film interposed
between the lithium anode and the electrolyte, and methods of
making the same, where the crosslinked polymer film is capable of
transmitting lithium ions. U.S. Pat. No. 5,314,765 to Bates
describes a thin layer of a lithium ion conducting ceramic coating
between the anode and the electrolyte. Yet further examples of
interfacial films for lithium containing anodes are described, for
example, in U.S. Pat. Nos. 5,387,497 and 5,487,959 to Koksbang;
U.S. Pat. No. 4,917,975 to De Jonghe et al.; U.S. Pat. No.
5,434,021 to Fauteux et al.; and U.S. Pat. No. 5,824,434 to
Kawakami et al.
[0007] A single protective layer of an alkali ion conducting glassy
or amorphous material for alkali metal anodes, for example, lithium
anodes in lithium-sulfur cells, is described in U.S. Pat. No.
6,02,094 to Visco et al. to address the problem of short cycle
life.
[0008] While a variety of techniques and components for protection
of lithium and other alkali metal anodes are known, especially in
rechargeable batteries, these protective coatings present
particular challenges. Since lithium batteries function by removal
and re-plating of lithium from a lithium anode in each
charge/discharge cycle, lithium ion must be able to pass through
any protective coating. The coating must also be able to withstand
morphological changes as material is removed and re-plated at the
anode.
[0009] Rechargeable (secondary) lithium batteries present a
particular challenge in connection with their use with aqueous
electrolytes. Water, and hydrogen ions, are particularly reactive
with lithium. Such devices, to be successful in achieving long
cycle life, will require very good protection of the lithium
anode.
[0010] Despite the various approaches proposed for forming lithium
anodes and forming interfacial and/or protective layers,
improvements are needed, especially for lithium anodes designed for
use in aqueous and/or air environments.
SUMMARY OF THE INVENTION
[0011] Rechargeable electrochemical cells, and more specifically,
rechargeable electrochemical cells comprising lithium anodes for
use in water and/or air environments are presented.
[0012] In one aspect, a series of electrochemical cells are
provided. In one embodiment, an electrochemical cell comprises an
anode comprising a base electrode material comprising lithium, a
single-ion conductive material, a polymeric layer between the base
electrode material and the single-ion-conductive material, and a
separation layer between the base electrode material and the
polymeric layer.
[0013] In another embodiment, an electrochemical cell comprises an
anode comprising a base electrode material comprising lithium, and
a multi-layered structure positioned between the anode and an
electrolyte of the cell. The multi-layered structure comprises at
least two first layers each of a single-ion conductive material, at
least two second layers each of a polymeric material, wherein the
at least two first layers and at least two second layers are
arranged in alternating order with respect to each other, and
wherein each layer of the multi-layered structure has a maximum
thickness of 25 microns.
[0014] In another embodiment, an electrochemical cell comprises an
anode comprising a base electrode material comprising lithium, a
single-ion conductive material, a polymeric layer between the base
electrode material and the single-ion-conductive material, a
separation layer between the base electrode material and the
polymeric layer, and an aqueous-based electrolyte in
electrochemical communication with the anode.
[0015] In another aspect, a method of electrical energy storage and
use is provided. In one embodiment, a method of electrical energy
storage and use comprises providing an electrochemical cell
comprising an anode with lithium as the active anode material, a
cathode, and an aqueous electrolyte in electrochemical
communication with the anode and cathode, and cycling the cell, by
alternatively discharging and charging the cell, at least three
times wherein, at the end of the 3.sup.rd cycle, the cell exhibits
at least 80% of the cell's initial capacity.
[0016] Other advantages and novel features of the present invention
will become apparent from the following detailed description of
various non-limiting embodiments of the invention when considered
in conjunction with the accompanying figures. In cases where the
present specification and a document incorporated by reference
include conflicting and/or inconsistent disclosure, the present
specification shall control. If two or more documents incorporated
by reference include conflicting and/or inconsistent disclosure
with respect to each other, then the document having the later
effective date shall control.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Non-limiting embodiments of the present invention will be
described by way of example with reference to the accompanying
figures, which are schematic and are not intended to be drawn to
scale. In the figures, each identical or nearly identical component
illustrated is typically represented by a single numeral. For
purposes of clarity, not every component is labeled in every
figure, nor is every component of each embodiment of the invention
shown where illustration is not necessary to allow those of
ordinary skill in the art to understand the invention. In the
figures:
[0018] FIG. 1 shows a structure for use in an electrochemical cell,
including a single-ion conductive layer and a polymer layer,
according to one embodiment of the invention;
[0019] FIG. 2 shows a structure for use in an electrochemical cell,
including several multi-layered structures, according to an
embodiment of the invention;
[0020] FIG. 3 shows a structure for use in an electrochemical cell,
including an embedded layer, according to an embodiment of the
invention;
[0021] FIG. 4 shows a structure for use in an electrochemical cell,
including an embedded layer comprising a multi-layered structure,
according to an embodiment of the invention;
[0022] FIG. 5 shows SEM images of Li anode surfaces after a
10.sup.th discharge, according to an embodiment of the
invention;
[0023] FIG. 6 shows a schematic diagram of an embodiment that
increases the barrier to passage of a species;
[0024] FIG. 7 shows a structure for use in an electrochemical cell,
including several multi-layered structures, embedded layers, and
separation layers, according to an embodiment of the invention;
and
[0025] FIG. 8 shows SEM images of Li anode surfaces after a
1.sup.st discharge, according to an embodiment of the
invention.
DETAILED DESCRIPTION
[0026] The present invention relates to electrochemical cells, and
more specifically, to rechargeable batteries including alkali metal
anodes for use in water and/or air environments. In most
embodiments described herein, lithium rechargeable batteries
(including lithium anodes) are described. However, wherever lithium
batteries are described herein, it is to be understood that any
analogous alkali metal battery (alkali metal anode) can be used.
Additionally, although rechargeable batteries are primarily
disclosed herein, non-rechargeable (primary) batteries are intended
to benefit from the invention as well. Furthermore, although the
invention is particularly useful in providing anode protection,
such that high-cycle life aqueous rechargeable batteries (batteries
using an aqueous-based electrolyte) are enabled, the invention is
also applicable to non-aqueous-based electrolyte batteries.
[0027] The invention provides techniques and components for
superior protection of and/or maintenance of electrodes (especially
lithium anodes) in rechargeable and other batteries. Components of
the invention provide, at least, one or more of the following
features: (1) protection of an electrode from one or more
components of an electrolyte that can react with or otherwise
hasten the demise of (shorten the cycle life of) the electrode
and/or overall device, (2) control over dissolution of anode
material into electrolyte (e.g., reduction of lithium to lithium
ion), and re-plating of electrode material from the electrolyte
(e.g., oxidation of lithium ion to lithium metal), at the anode,
and/or (3) superior control of desirable passage of components from
the electrode to the electrolyte (e.g., lithium ion) while
inhibiting passage of undesirable components from the electrolyte
to the electrode that can damage the electrode.
[0028] In one embodiment, an electrochemical cell of the invention
includes an anode comprising lithium, and a multi-layered structure
positioned between the anode and an electrolyte of the cell. In one
specific embodiment providing superior interaction between the
multi-layered structure and the electrode, the multi-layered
structure includes at least a first single-ion conductive material
layer (e.g., a lithiated metal layer), and at least a first
polymeric layer positioned between the anode and the single-ion
conductive material. In this embodiment, the multi-layered
structure can include several sets of alternating single-ion
conductive material layers and polymeric layers. The multi-layered
structures can allow passage of lithium ions, while limiting
passage of certain chemical species that may adversely affect the
anode (e.g., water). The cells may also include an separation layer
(e.g., a plasma-treated layer) positioned between the anode and the
multi-layered structure. This separation layer can act as a
temporary or permanent protective layer, e.g., to cause uniform
depletion and/or re-plating of lithium across the surface of the
anode.
[0029] As noted in the embodiment thus far described, a lithium
electrode, with or without a separation layer, is first directly
addressed by a polymeric layer. On the side of the polymeric layer
opposite that of the electrode, a single-ion conductive material
layer is provided. Additional layers can be further provided. This
arrangement can provide significant advantage, as polymers can be
selected that impart flexibility to the system where it can be
needed most, namely, at the surface of the electrode where
morphological changes occur upon charge and discharge. In one
specific embodiment, the polymer is particularly pliable and/or
elastic (non-brittle) to provide a particularly durable, robust,
rechargeable battery. In this arrangement the polymer can have at
least one of the following properties, or a combination of any
number of these properties: a Shore A hardness of less than 100,
less than 80, less than 60, less than 40, or less than 20, (or a
Shore A hardness between 0 and 10, between 10 and 20, between 20
and 30, between 30 and 40, between 40 and 50, between 50 and 60,
between 60 and 70, between 70 and 80, between 80 and 90, or between
90 and 100), or a Shore D hardness of less than 100, less than 80,
less than 60, less than 40, or less than 20 (or a Shore D hardness
between 0 and 10, between 10 and 20, between 20 and 30, between 30
and 40, between 40 and 50, between 50 and 60, between 60 and 70,
between 70 and 80, between 80 and 90, or between 90 and 100); a
Young's Modulus (elastic modulus) of less than 10 GPa, less than 5
GPa, less than 3 GPa, less than 1 GPa, less than 0.1 GPa, or less
than 0.01 GPa (or a Young's Modulus between 0.01 and 0.1 GPa,
between 0.1 and 1 GPa, between 1 and 2.5 GPa, between 2.5 and 5
GPa); and an average fracture toughness of greater than 0.1
MN/m.sup.3/2, greater than 0.5 MN/m.sup.3/2, greater than 1.0
MN/m.sup.3/2, greater than 2.0 MN/m.sup.3/2, greater than 3.0
MN/m.sup.3/2, or greater than 5 MN/m.sup.3/2 (e.g., as measured at
room temperature and atmospheric pressure). Appropriate polymers
may also be chosen based on one or more properties relevant to use
in an environment as described herein, such as: glass transition
temperature (T.sub.g), melting point (T.sub.m), strength (e.g.,
compressional, tensile, flexural, and yield strength), elongation,
plasticity, and hardness (e.g., as measured by a Shore A or Shore D
durometer, or the Rockwell hardness test). This arrangement,
comprising a depletable/re-platable electrode, polymer protective
layer, and single-ion-conductive layer as a sub-combination of an
overall protective structure or overall battery, adds significant
advantage. In this and other arrangements, single-ion-conductive
layers can be selected among those described herein and generally
known in the art including glasses, lithiated metal layers, and the
like.
[0030] Most single thin film materials, when deposited on the
surface of a Li anode, do not have all of the necessary properties
of passing Li ions, forcing a substantial amount of the Li surface
to participate in current conduction, protecting the metallic Li
anode against certain species (e.g., liquid electrolyte and/or
polysulfides generated from a sulfur-based cathode) migrating from
the cathode, and impeding high current density-induced surface
damage. The present inventors have developed solutions to these
problems through several embodiments of the invention, including
the use of multi-layered anode stabilization layers (electrode
stabilization), embedded Li layers (e.g., embodiments including a
first Li layer, a Li conducting and electron insulating layer, and
a second Li layer), and separation layers (e.g., plasma treated
layers), as discussed in greater detail below.
[0031] FIG. 1 shows one example of an electrode protective
arrangement of the invention, exemplified as a multi-layered anode
stabilization layer structure. In the embodiment illustrated in
FIG. 1, structure 10 includes anode 20 comprising a base electrode
material (e.g., lithium), and multi-layered structure 22 covering
the anode. In some cases herein, the anode is referred to as an
"anode based material," "anode active material," or the like, and
the anode along with any protective structures are referred to
collectively as the "anode." All such descriptions are to be
understood to form part of the invention. In this particular
embodiment, multi-layered structure 22 includes single-ion
conductive material 50, polymeric layer 40 positioned between the
base electrode material and the single-ion-conductive material, and
separation layer 30 (e.g., a layer resulting from plasma treatment
of the electrode ) positioned between the electrode and the
polymeric layer. Multi-layered structures can allow passage of
lithium ions and may impede the passage of other components that
may otherwise damage the anode. Advantageously, multi-layered
structures can reduce the number of defects and thereby force a
substantial amount of the Li surface to participate in current
conduction, impede high current density-induced surface damage,
and/or act as an effective barrier to protect the anode from
certain species (e.g., electrolyte and/or polysulfides), as
discussed in greater detail below.
[0032] Anode 20 can comprise a base electrode material such as
lithium metal, which can serve as the anode active material. The
lithium metal may be in the form of, e.g., a lithium metal foil or
a thin lithium film that has been deposited on a substrate, as
described below. The lithium metal may also be in the form of a
lithium alloy such as, for example, a lithium-tin alloy or a
lithium aluminum alloy.
[0033] In this and other embodiments, the thickness of the anode
may vary from, e.g., about 2 to 200 microns. For instance, the
anode may have a thickness of less than 200 microns, less than 100
microns, less than 50 microns, less than 25 microns, less than 10
microns, or less than 5 microns. The choice of the thickness may
depend on cell design parameters such as the excess amount of
lithium desired, cycle life, and the thickness of the cathode
electrode. In one embodiment, the thickness of the anode active
layer is in the range of about 2 to 100 microns. In another
embodiment, the thickness of the anode is in the range of about 5
to 50 microns. In another embodiment, the thickness of the anode is
in the range of about 5 to 25 microns. In yet another embodiment,
the thickness of the anode is in the range of about 10 to 25
microns.
[0034] The device illustrated in FIG. 1. may further comprise a
substrate, as is known in the art, on the surface of the anode
opposite that of the multi-layer structure. Substrates are useful
as a support on which to deposit the anode active material, and may
provide additional stability for handling of thin lithium film
anodes during cell fabrication. Further, in the case of conductive
substrates, a substrate may also function as a current collector
useful in efficiently collecting the electrical current generated
throughout the anode and in providing an efficient surface for
attachment of electrical contacts leading to an external circuit. A
wide range of substrates are known in the art of anodes. Suitable
substrates include, but are not limited to, those selected from the
group consisting of metal foils, polymer films, metallized polymer
films, electrically conductive polymer films, polymer films having
an electrically conductive coating, electrically conductive polymer
films having an electrically conductive metal coating, and polymer
films having conductive particles dispersed therein. In one
embodiment, the substrate is a metallized polymer film. In other
embodiments, described more fully below, the substrate may be
selected from non-electrically-conductive materials.
[0035] The layers of the anode structure 10 of the present
invention may be deposited by any of a variety of methods generally
known in the art, such as physical or chemical vapor deposition
methods, extrusion, and electroplating. Examples of suitable
physical or chemical vapor deposition methods include, but are not
limited to, thermal evaporation (including, but not limited to,
resistive, inductive, radiation, and electron beam heating),
sputtering (including, but not limited to, diode, DC magnetron, RF,
RF magnetron, pulsed, dual magnetron, AC, MF, and reactive),
chemical vapor deposition, plasma enhanced chemical vapor
deposition, laser enhanced chemical vapor deposition, ion plating,
cathodic arc, jet vapor deposition, and laser ablation.
[0036] Deposition of the layers may be carried out in a vacuum or
inert atmosphere to minimize side reactions in the deposited layers
which could introduce impurities into the layers or which may
affect the desired morphology of the layers. In some embodiments,
anode active layers and the layers of multi-layered structures are
deposited in a continuous fashion in a multistage deposition
apparatus.
[0037] Specifically, methods for depositing anode 20 (e.g., in the
case of an alkali metal anode such as lithium) onto a substrate
include methods such as thermal evaporation, sputtering, jet vapor
deposition, and laser ablation. Alternatively, where the anode
comprises a lithium foil, or a lithium foil and a substrate, these
can be laminated together by a lamination process as known in the
art, to form an anode layer.
[0038] In some embodiments, the single-ion conductive material is
non-polymeric. E.g., in certain embodiments, the single-ion
conductive material 50 is defined in part or in whole by a metal
layer that is highly conductive toward lithium and minimally
conductive toward electrons. In other words, the single-ion
conductive material may be one selected to allow lithium ions, but
to impede electrons, from passing across the layer. The metal layer
may comprise a metal alloy layer, e.g., a lithiated metal layer
especially in the case where a lithium anode is employed. The
lithium content of the metal alloy layer may vary from about 0.5%
by weight to about 20% by weight, depending, for example, on the
specific choice of metal, the desired lithium ion conductivity, and
the desired flexibility of the metal alloy layer. Suitable metals
for use in the single-ion conductive material include, but are not
limited to, Al, Zn, Mg, Ag, Pb, Cd, Bi, Ga, In, Ge, Sb, As, and Sn.
Sometimes, a combination of metals, such as the ones listed above,
may be used in a single-ion conductive material.
[0039] In other embodiments, the single-ion conductive material may
include a ceramic layer, for example, a single ion conducting glass
conductive to lithium ions. Suitable glasses include, but are not
limited to, those that may be characterized as containing a
"modifier" portion and a "network" portion, as known in the art.
The modifier may include a metal oxide of the metal ion conductive
in the glass. The network portion may include a metal chalcogenide
such as, for example, a metal oxide or sulfide. Single-ion
conductive layers may include glassy layers comprising a glassy
material selected from the group consisting of lithium nitrides,
lithium silicates, lithium borates, lithium aluminates, lithium
phosphates, lithium phosphorus oxynitrides, lithium silicosulfides,
lithium germanosulfides, lithium oxides (e.g., Li.sub.2O, LiO,
LiO.sub.2, LiRO.sub.2, where R is a rare earth metal), lithium
lanthanum oxides, lithium titanium oxides, lithium borosulfides,
lithium aluminosulfides, and lithium phosphosulfides, and
combinations thereof. In one embodiment, the single-ion conductive
layer comprises a lithium phosphorus oxynitride in the form of an
electrolyte. Electrolyte films of lithium phosphorus oxynitride
suitable for use as the single ion conductive material 50 are
disclosed, for example, in U.S. Pat. No. 5,569,520 to Bates. The
selection of the single ion conducting material will be dependent
on a number of factors including, but not limited to, the
properties of electrolyte and cathode used in the cell.
[0040] For cells used in a water and/or air environment, such as a
rechargeable battery with an aqueous-based electrolyte, the
single-ion conductive material may be constructed so as to impede
the passage of hydrogen ions (protons) across its layer. For
instance, during discharge protons may move against the electric
field in a protective layer (e.g., a multi-layered structure) of a
cell. However, during charge, the electric field may accelerate the
penetration of protons across the protective layer. Eventually
protons may reach a Li anode layer and generate, e.g., hydrogen gas
or other species, which may form bubbles and can cause
delamination, or other undesirable effects, in a multi-layered
structure. As discussed in more detail below, the single-ion
conductive layer may be combined with other materials (e.g.,
impregnated with a polymer) to impede the passage of hydrogen ions
and/or or electrons, while permitting the passage of lithium
ions.
[0041] The thickness of a single-ion conductive material layer
(e.g., within a multi-layered structure) may vary over a range from
about 1 nm to about 10 microns. For instance, the thickness of the
single-ion conductive material layer may be between 1-10 nm thick,
between 10-100 nm thick, between 100-1000 nm thick, between 1-5
microns thick, or between 5-10 microns thick. The thickness of a
single-ion conductive material layer may be no greater than, e.g.,
10 microns thick, no greater than 5 microns thick, no greater than
1000 nm thick, no greater than 500 nm thick, no greater than 250 nm
thick, no greater than 100 nm thick, no greater than 50 nm thick,
no greater than 25 nm thick, or no greater than 10 nm thick. In
some cases, the single-ion conductive layer has the same thickness
as a polymer layer in a multi-layered structure.
[0042] The single-ion conductive layer may be deposited by any
suitable method such as sputtering, electron beam evaporation,
vacuum thermal evaporation, laser ablation, chemical vapor
deposition (CVD), thermal evaporation, plasma enhanced chemical
vacuum deposition (PECVD), laser enhanced chemical vapor
deposition, and jet vapor deposition. The technique used may depend
on the type of material being deposited, the thickness of the
layer, etc.
[0043] In some embodiments, single-ion conducting layers can be
treated with a polymer such that pinholes and/or nanopores of the
single-ion conducting layers may be filled with the polymer. Such
embodiments can impede the diffusion of certain species (e.g.,
electrolyte and/or polysulfides) towards the anode, e.g., by
increasing the distance, and tortuosity, through which such a
species would need to pass to penetrate the entire multi-layer
arrangement to arrive at the anode, as discussed in greater detail
below.
[0044] The thickness of a polymer layer (e.g., within a
multi-layered structure) may vary over a range from about 0.1
microns to about 10 microns. For instance, the thickness of the
polymer layer may be between 0.1-1 microns thick, between 1-5
microns thick, or between 5-10 microns thick. The thickness of a
polymer layer may be no greater than, e.g., 10 microns thick, no
greater than 5 microns thick, no greater than 2.5 microns thick, no
greater than 1 micron thick, no greater than 0.5 microns thick, or
no greater than 0.1 microns thick.
[0045] In some embodiments including a multi-layered structure
having more than one polymer layer, the thicknesses of the polymer
layers can vary within the structure. For instance, in some cases,
the polymer layer closest to the anode layer (e.g., a Li reservoir)
is thicker than the other polymer layers of the structure. This
embodiment can, for example, stabilize the anode by allowing
lithium ions to plate out more uniformly across the surface of the
anode during charge.
[0046] A polymer layer may be deposited by method such as electron
beam evaporation, vacuum thermal evaporation, laser ablation,
chemical vapor deposition, thermal evaporation, plasma assisted
chemical vacuum deposition, laser enhanced chemical vapor
deposition, jet vapor deposition, and extrusion. The polymer layer
may also be deposited by spin-coating techniques. A method for
depositing crosslinked polymer layers includes flash evaporation
methods, for example, as described in U.S. Pat. No. 4,954,371 to
Yializis. A method for depositing crosslinked polymer layers
comprising lithium salts may include flash evaporation methods, for
example, as described in U.S. Pat. No. 5,681,615 to Affinito et al.
The technique used for depositing polymer layers may depend on the
type of material being deposited, the thickness of the layer,
etc.
[0047] As noted in the description with respect to FIG. 1 thus far,
in one particular embodiment, the protective structure separating
anode 20 from electrolyte 60 includes a polymer layer adjacent the
anode (or separation layer) 30. In other arrangements, a polymer
layer need not be the first layer adjacent the anode or separation
layer. Various arrangements of the invention, including various
multi-layered structures, are described below in which the first
layer adjacent the anode may or may not be polymeric. It is to be
understood that in all arrangements where any particular
arrangement of layers is shown, alternate ordering of layers is
within the scope of the invention. Notwithstanding this, one aspect
of the invention includes the particular advantages realized by a
non-brittle polymer immediately adjacent the anode or separation
layer.
[0048] In some embodiments, multi-layered structures protect the
anode better than any individual layer that is included in the
structure. For instance, each of the layers of a multi-layered
structure, e.g., the single-ion conducting layers, the polymer
layers, or the separation layer, may possess desirable properties,
but at the same time may be most effective when complemented by
other components with different properties. For example, single-ion
conducting layers, especially vacuum deposited single-ion
conducting layers, may be flexible as thin films, but when
deposited as thicker layers, may include defects such as pinholes
and/or roughness, and may crack when handled. Polymer layers, and
especially crosslinked polymer layers, for example, can provide
very smooth surfaces, may add strength and flexibility, and may be
electron insulating, but may pass certain solvents and/or liquid
electrolytes. Accordingly, these are examples of layers that can
complement each other in an overall improved protective
structure.
[0049] Accordingly, in another embodiment, the invention provides a
multi-layered electrode stabilization or protection structure that
provides many advantages over existing electrode protective
structures. In much of the description herein, the structure is
referred to as an "anode stabilization" structure, but it is to be
understood that the structure can be used for any electrode under
suitable conditions as would be understood by those of ordinary
skill in the art when taking into consideration the function of a
particular electrode. Multi-layered electrode stabilization
structures of the invention, according to this embodiment, are
designed to minimize defects that might otherwise exist inherently
in prior electrode protective structures, or that might exist
inherently in electrode protective structures using the same or
similar materials as those used in protective structures of the
current invention, but arranged differently. For example, single
ion-conductive layers (or other components of a device as described
herein) may include pinholes, cracks and/or grain boundary defects.
Once these defects are formed, they can grow/propagate through the
entire thickness of the film as the film grows and may become worse
as the film grows thicker. By separating thin single ion-conductive
layers from each other with thin, pinhole free, smooth polymer
layers, the defect structure in each single ion-conductive layer
can be decoupled from the defect structure in every other single
ion-conductive layer by an intervening polymer layer. Thus, at
least one or more of the following advantages are realized in such
a structure: (1) it is less likely for defects in one layer to be
directly aligned with defects in another layer, and typically any
defect in one layer is substantially non-aligned with a similar
defect in another layer; (2) any defects in one single
ion-conductive layer typically are much smaller and/or less
detrimental than they would otherwise be in a thicker layer of
otherwise similar or identical material. Where alternating
single-ion conductive layers and polymer layers are deposited atop
each other in a fabrication process, each single-ion conductive
layer has a smooth, pinhole free, polymer surface upon which to
grow. In contrast, where the single-ion conductive layer to be
deposited atop another single-ion conductive layer (or continuously
deposited as a single, thicker layer), defects in an underlying
layer can serve to instigate defects in growth in a layer deposited
atop an underlying layer. That is, whether a protective structure
is built with thicker single-ion conductive layers or multiple
single-ion conductive layers atop each other, defects can propagate
through the thickness, or from layer to layer, as the structure
grows, resulting in larger defects, and defects that propagate
directly or substantially directly throughout the entire structure.
In this arrangement, the single ion-conductive layers can also grow
with fewer defects than would occur if they were deposited directly
onto the rougher Li or electrolyte layers, particularly where the
arrangement of FIG. 1 is employed in which the first electrode
stabilization layer addressing the electrode is the polymer layer.
Accordingly, in this arrangement, ion-conductive layers can be made
that have overall fewer defects, defects that are not aligned with
defects in nearest other ion-conductive layers and, where defects
exist, they are typically significantly less detrimental (e.g.,
smaller) than would otherwise exist in a continuously-grown,
thicker structure or layers of the same or similar material
deposited on top of each other.
[0050] A multi-layered electrode stabilization structure can act as
a superior permeation barrier by decreasing the direct flow of
species (e.g., electrolyte and polysulfide species) to the Li
anode, since these species have a tendency to diffuse through
defects or open spaces in the layers. Consequently, dendrite
formation, self discharge, and loss of cycle life can be
reduced.
[0051] Another advantage of a multi-layered structure includes the
mechanical properties of the structure. The positioning of a
polymer layer adjacent a single-ion conductive layer can decrease
the tendency of the single-ion conductive layer to crack, and can
increase the barrier properties of the structure. Thus, these
laminates may be more robust towards stress due to handling during
the manufacturing process than structures without intervening
polymer layers. In addition, a multi-layered structure can also
have an increased tolerance of the volumetric changes that
accompany the migration of lithium back and forth from the anode
during the cycles of discharge and charge of the cell.
[0052] The ability of certain species that can be damaging to the
anode (e.g., electrolytes and/or polysulfides) to reach the anode
can also be decreased by providing repeated layers of single-ion
conductive layers and polymer layers in a multi-layered structure.
When a species encounters a defect-free portion of a single-ion
conductive layer, transport of the species towards the anode is
possible if the species diffuses laterally through a very thin
polymer layer to encounter a defect in a second single-ion
conductive layer. Since lateral diffusion through ultra-thin layers
is very slow, as the number of single-ion conductive/polymer layer
pairs increases, the rate of diffusion of species becomes extremely
small (e.g., the amount of penetration across the layer decreases).
For instance, in one embodiment, permeation of a species through
polymer/single-ion conductive/polymer 3-layer structures can be
reduced by three orders of magnitude over a single single-ion
conductive layer alone (e.g., even though layers alone may have
poor barrier properties). In another embodiment, a
polymer/single-ion conductive/polymer/single-ion conductive/polymer
5-layer structure may have more than five orders of magnitude
reduction of permeation of a species compared to that in a single
single-ion conductive layer. By contrast, permeation of the same
species through a double-thick single-ion conductive layer may
actually increase. These significant reductions in permeation of
destructive species through the electrode stabilization layer can
increase as the number of layers increases where the thickness of
individual layers decreases. That is, in comparison to a two-layer
structure of a single-ion conductive layer and polymer layer of a
particular, overall thickness, a ten-layer structure of alternating
single-ion conductive layers and polymer layers of the same overall
thickness can vary significantly decreased permeation of unwanted
species through the layer. Specific arrangements are described
below, and a principal involved in the increased barrier to passage
of these species is schematically illustrated below in FIG. 6.
Because of the significant advantage realized by electrode
stabilization protection of the invention, overall lower amounts of
material can be used in a particular protective structure, as
compared to prior art structures. Accordingly, at a particular
level of electrode protection needed in a particular battery
arrangement, a significantly smaller mass of overall electrode
stabilization materials can be employed, significantly reducing
overall battery weight.
[0053] A multi-layered structure can include various numbers of
polymer/single-ion conductive pairs as needed. Generally, a
multi-layered structure can have n polymer/single-ion conductive
pairs, where n can be determined based on a particular performance
criteria for a cell. E.g., n can be an integer equal to or greater
than 1, or equal to or greater than 2, 3, 4, 5, 6, 7, 10, 15, 20,
40, 60, 100, or 1000, etc. In some embodiments, a multi-layered
structure can include greater than 4, greater than 10, greater than
25, greater than 50, greater than 100, greater than 200, greater
than 500, greater than 1000, greater than 2000, greater than 3000,
greater than 5000, or greater than 8000 polymer/single-ion
conductive pairs. For example, in one particular embodiment,
greater than 10,000 polymer/single-ion conductive pairs were
fabricated.
[0054] FIG. 2 shows an example of a multi-layered electrode
stabilization structure including multiple polymer and single-ion
conductive layers. In the embodiment illustrated in FIG. 2,
structure 11 includes anode 20 comprising a base electrode material
(e.g., lithium), and multi-layered structure 24 positioned between
the anode and an electrolyte 60 of the cell. The multi-layered
structure comprises at least two first layers each of a single-ion
conductive material and at least two second layers each of a
polymeric material. For example, multi-layered structure 24
includes polymer layers 40 and 42, and single-ion conductive layers
50 and 52. As shown in FIG. 2, the two layers of polymeric material
and two layers of single-ion conductive material are arranged in
alternating order with respect to each other. Structure 11 may
optionally comprise a separation layer (e.g., a plasma treated
layer) between the base electrode material and the polymeric layer
(not shown in FIG. 2; illustrated in FIG. 1).
[0055] Structure 11 can also include additional multi-layered
structures such as multi-layered structure 26, comprising polymer
layers 44 and 46, and single-ion conductive layers 54 and 56.
Multi-layered structures 24 and 26 can be combined to form a single
multi-layered, or can be constructed together as one, unitary
multi-layered structure, including four layers each of a single-ion
conductive material and for layers each of a polymeric material. In
other embodiments, structures can include other numbers of
alternating single-ion conductive layers and polymer layers. For
instance, a multi-layered structure may include n first layers each
of a single-ion conductive material and n second layers each of a
polymeric material, in alternating arrangement, where n is greater
than or equal to 2. E.g., n may equal at least 2, 3, 4, 5, 6, or 7,
10, 15, 20, 40, 60, 100, etc.
[0056] In other embodiments, a multi-layered structure may include
a greater number of polymer layers than single-ion conductive
layers, or a greater number of single-ion conductive layers than
polymer layers. For example, a multi-layered structure may include
a n polymer layers and n+1 single-ion conductive layers, or n
single-ion conductive layers and n+1 polymer layers, where n is
greater than or equal to 2. E.g., n may equal 2, 3, 4, 5, 6, or 7,
etc. However, as described above, it is immediately adjacent at
least one polymer layer and, in at least 50%, 70%, 90%, or 95% of
the ion-conductive layers, such layers are immediately adjacent a
polymer layer on either side.
[0057] As mentioned, multi-layered electrode stabilization
structures can provide significant advantage where a particular
amount of materials defining the structure are arranged in thinner,
and greater numbers of, form. In some embodiments, each layer of
the multi-layered structure has a maximum thickness of less than
100 microns, less than 50 microns, less than 25 microns, less than
10 microns, less than 1 micron, less than 100 nanometers, less than
10 nanometers, or less than 1 nanometer. Sometimes, the thickness
of a single type of layer may be the same in a multi-layered
structure. For instance, polymer layers 40 and 42 may have the same
thickness in multi-layered structure 24. In other embodiments, the
thickness of a single type of layer may be different in a
multi-layered structure, e.g., polymer layers 40 and 42 may have
different thicknesses in multi-layered structure 24. The
thicknesses of different types of layers in a multi-layered
structure may be the same in some cases, or different in other
cases. For example, the thicknesses of polymer layers 40 and 42 may
be different than the thickness of single-ion conductive layers 50
and 52. Those of ordinary skill in the art can select appropriate
materials and thicknesses of layers in combination with the
description herein.
[0058] A multi-layered structure may have various overall
thicknesses that can depend on, for example, the electrolyte, the
cathode, or the particular use of the electrochemical cell. In some
cases, a multi-layered structure can have an overall thickness of
less than or equal to 1 cm, less than or equal to 5 mm, less than
or equal to 1 mm, less than or equal to 700 microns, less than or
equal to 300 microns, less than or equal to 250 microns, less than
or equal to 200 microns, less than or equal to 150 microns, less
than or equal to 100 microns, less than or equal to 75 microns, or
less than or equal to 50 microns. It may also be desirable to have
a multi-layered structure having a certain thickness with a certain
number of polymer/single-ion conductive material pairs. For
instance, in one embodiment, a multi-layered structure may have a
thickness of less than 1 mm, and may include greater than 10
polymer/single-ion conductive material pairs. In another
embodiment, a multi-layered structure may have a thickness of less
than 0.5 mm, and may include greater than 50 polymer/single-ion
conductive material pairs. It is to be understood that a variety of
embodiments are provided by the invention, each including specific
combinations of overall electrode stabilization thickness,
thicknesses of individual layers, numbers of individual layers,
etc. as described herein.
[0059] As noted, multi-layered structures can protect the anode by
decreasing water and/or oxygen penetration across the layers. For
instance, a typical PVD oxide coating of a few hundred Angstroms
thick on 12 micron thick PET surface can decrease water and/or
oxygen permeation by a factor of 30-40 times compared to a surface
without the PVD oxide coating. The water and/or oxygen permeation
decrease resulting from a typical 1 micron thick acrylate coating
(coated monomer that is subsequently polymerized) on a 12 .mu.m
thick PET surface may be barely measurable. However, applying the
acrylate coating over the oxide layer in the PET/oxide structure
can result in a further 10-20 fold decrease in water and/or oxygen
permeation. Two polymer/oxide pairs can decrease water and/or
oxygen permeation by more than 100 fold over a single PVD oxide
coating, while 5 pairs can reduce oxygen permeation by more than 5
orders of magnitude. As such, electrochemical cells including
multi-layered structures are well-suited for use in water and/or
oxygen or air environments.
[0060] Another embodiment of the invention includes an embedded
layer (e.g., of a single-ion conductive material) positioned
between two layers of base electrode materials. This is referred to
as a "lamanode" structure. FIG. 3 shows structure 12 including
anode 20 comprising a first layer of a base electrode material
(e.g., lithium, also referred to as a Li reservoir), embedded layer
70, and a second layer 22 comprising the base electrode material (a
working Li layer). As illustrated in the embodiment shown in FIG.
3, the second layer is positioned between the anode 20 and
electrolyte 60. The second layer may be either in direct contact
with the electrolyte, or in indirect contact with the electrolyte
through some form of a surface layer (e.g., an electrode
stabilization structure, for example, one described herein ). The
function of the bi-layer anode structure, with each anode portion
separated by an imbedded layer 70, will become clearer from the
description below. It is noted that although layer 70 is
illustrated and described as "embedded" in this description, it is
noted that the layer need not be partially or fully embedded. In
many or most cases, layer 70 is a substantially thin, two-sided
structure coated on each side by anode material, but not covered by
anode material at its edges. In general, in operation of the
arrangement shown in FIG. 3, some or all of second layer (portion)
23 of the anode is "lost" from the anode upon discharge (when it is
converted to lithium ion which moves into the electrolyte). Upon
charge, when lithium ion is plated as lithium metal onto the anode,
it is plated as portion 23 (or at least some portion of portion 23)
above layer 70. Those of ordinary skill in the art are aware that
in batteries such as those described herein, there is a small
amount of overall lithium loss on each charge/discharge cycle of
the battery. In the arrangement illustrated in FIG. 3, the
thickness of layer 23 (or the mass of layer 23) can be selected
such that most or all of layer 23 is lost upon full discharge of
the battery (full "satisfaction" of the cathode; the point at which
the cathode can no longer participate in a charging process due to
limitations that would be understood by those of ordinary skill in
the art). Layer 70 is selected to be one that is conductive to
lithium ions. The embedded layer can shield the bottom Li layer
from damage as the high Li.sup.+ flux of the first cycle damages
the top Li layer surface. Accordingly, once all of layer 23 is
consumed in a particular discharge cycle, further discharge results
in oxidation of lithium from layer 21, passage of lithium ion
through layer 70, and release of lithium ion into the electrolyte.
Of course, layer 23 need not be of a particular mass such that all
or nearly all of it is consumed on first discharge. It may take
several discharge/charge cycles, and inherent small amount of
lithium loss through each cycle, to result in the need to draw
lithium from section 21 through layer 70 and into the electrolyte.
But once that occurs, then each subsequent charge/discharge cycle
will generally progress as follows.
[0061] Through most of the discharge cycle lithium will be removed
from section 23 and, at the very end of the discharge cycle, a
small amount of lithium will be required to be drawn from section
21 through layer 70 to make up for the amount of lithium lost in
the most recent charge/discharge cycle. Upon charge, lithium will
be plated upon layer 70 as material 23 in an amount very slightly
less than that removed from the anode during discharge. The
electrode stabilization layer 70 can be made of any suitable
material selected, by those of ordinary skill in the art, in
accordance with the function described herein. Generally, layer 70
will be made of a material that is single-ion conductive but that
will not allow lithium metal itself to pass. In some embodiments
the material is non-electrically-conductive, for reasons described
below.
[0062] The ratio of the thickness of first and second layers of
base electrode materials can be calculated based on, e.g., a
required "depth of discharge" (amount of lithium metal consumed) of
the first discharge. The ratio may be, for instance, between the
range of 0.2 to 0.4. The thickness of anode 20 may be, for
instance, less than 100 microns, less than 50 microns, less than 25
microns, or less than 10 microns. In some embodiments, anode 20 can
have a thickness between 10 and 30 microns.
[0063] In some embodiments, embedded layer 70 may have a thickness
between 0.01-1 microns, and may depend on, e.g., the type of
material used to form the embedded layer and/or the method of
depositing the material. For example, the thickness of the embedded
layer may be between 0.01-0.1 microns, between 0.1-0.5 microns, or
between 0.5-1 micron. In other embodiments, thicker embedded layers
are included. For example, the embedded layer can have a thickness
between 1-10 microns, between 10-50 microns, or between 50-100
microns. In some cases, the embedded material can be formed of a
polymer, e.g., including ones listed above that are lithium ion
conductive. The polymer film can be deposited using techniques such
as vacuum based PML, VMT or PECVD techniques. In other cases, an
embedded layer can comprise a metal or semi-conductor material.
Metals and semi-conductors can be, for example, sputtered. Those of
ordinary skill in the are can choose suitable materials,
thicknesses, and methods of depositing embedded layers based on
routine experimentation in combination with disclosure herein.
[0064] In one embodiment, layer 70 is an anode stabilization
structure of multi-layer form as described above in connection with
FIG. 2 and as described more fully below.
[0065] The second layer 23 of lithium can be used to protect the
surface of anode 20 (e.g., a Li surface) by limiting the current
density-induced surface damage to a thin Li layer above the
embedded layer 70. For instance, layer 23 can lithiate the cathode
(be removed from the anode in the form of lithium ion) on the first
cycle, e.g., under extremely high Li.sup.+ flux, instead of causing
anode 20 to lithiate the cathode, thereby protecting anode 20. In
each charge/discharge cycle (after the point is reached at which
more lithium than is present in layer 23 is removed from the anode
during discharge) only a small amount of lithium is removed from
section 21 and no lithium is re-plated at section 21. This can
eliminate or reducing the numbers of defects, cracks, pinholes
and/or dendrites forming on the surface of anode 20 during the
cathode lithiation. Structure 12 can improve the cycle life of the
cell compared to a cell including an anode without a second layer
of Li and/or an embedded layer, as described in further detail
below.
[0066] As mentioned, layer 70 should be able to pass lithium ions.
It can be made of material including ceramic, glass, or polymer
layer (or a multi-layered structure, as described below) that is
conductive to Li ions and, in some embodiments, it substantially
impedes the passage of electrons across the layer. By
"substantially impedes", in this context, it is meant that in this
embodiment the material allows lithium ion flux at least ten times
greater than electron passage. As noted, in other embodiments the
material can be electron conductive.
[0067] Referring again to FIG. 3, anode 12 can function with any of
a variety of current collectors (not shown). Current collectors are
well known to those of ordinary skill in the art and can be readily
selected from suitable materials based upon this disclosure. In one
arrangement, a current collector addresses the bottom surface of
section 21 of anode 20 (the side opposite electrolyte 60). In
another arrangement, an edge collector is used, which can be
positioned on one or multiple edges, i.e., a side, as illustrated
in FIG. 3, including section 21, material 70, and section 23. In
other arrangements, both a bottom collector and one or more edge
collectors can be used. Where only a bottom collector is used,
material 70 should be electronically conductive as well as lithium
ion conductive. Where an edge collector is used material 70 can be
selected to substantially inhibit electron passage.
[0068] In one particular set of embodiments, an edge collector is
used and provides advantage in anode stabilization/protection. One
such arrangement is illustrated in FIG. 4, where an embedded
stabilization structure 24 (itself analogous to section 70 of FIG.
3), separates the Li anode 20 into one portion 21, (the Li
reservoir), from a second portion of Li, layer 23 (the working Li
layer). The embedded layer, e.g., multi-layered structure 24, the
Li reservoir, and layer 22 can all be electrically connected at the
edge current collector 80. In the arrangement illustrated in FIG.
4, a bottom current collector is not used.
[0069] During operation of an electrochemical cell as illustrated
in FIG. 4, or another cell including an embedded layer between two
base electrode material layers and with an edge collector, during
discharge, current enters the anode through the working
Li/electrolyte interface. However, the embedded layer can
substantially block electron current while allowing passage of Li
ions. For instance, the flow of electron current, as illustrated by
the arrows in FIG. 4, may be substantially impeded through the
electrode stabilization layer, to section 21 of the anode, and to
one or more current collectors. Thus, a substantial amount or
substantially all of the current can pass through the working Li
layer 23 to the edge collector 80, e.g., in the direction of arrow
84, while a much smaller portion (or essentially no electron flow)
passes through stabilization material 24 to the Li reservoir 21 to
the edge collector, e.g., in the direction of arrows 82 and 89, or
to a bottom current collector (not shown) in the direction of
arrows 86 and 88. As noted, in some embodiments, the working Li
layer, prior to first discharge of the cell 23, comprises more
active electrode species than is depleted upon full discharge of
the counter electrode, e.g., as to satisfy the cathode upon cathode
lithiation. E.g., the working Li layer may include an amount of Li,
prior to first discharge of the cell, such that greater than 50%,
greater than 70%, greater than 90%, or greater than 95% of the Li
of the working layer 23 is electrochemically dissolved upon the
first discharge.
[0070] On charging, lithium ion is plated, as lithium metal, at the
anode, as described above in connection with FIG. 3. Since the
electrolyte/working Li layer23/edge collector 80 is the lowest
resistance path for electron current, most current takes this path
once Li ion reaches the working Li layer and is reduced. Current
density induced damage/corrosion is significantly minimized since
any such processes occur only or primarily at the
electrolyte/working Li 23 interface, while the embedded layer 21
remains undamaged. As noted above in connection with FIG. 3, as the
working Li layer gradually loses a small percentage of Li during
each cycle, this Li is replaced by a flow of Li ions across the
embedded layer 24 and into the electrolyte. This results in more
even loss/re-plating of lithium during discharge/charge cycles,
therefore minimizing damage/corrosion of the anode and,
importantly, the damage/corrosion can be inhibited or made to be
essentially zero in Li reservoir 21. As a result, the Li reservoir
does not degenerate into isolated Li islands surrounded by
corrosion byproducts, as can be the case with use of a single layer
Li anode.
[0071] A variety of arrangements can be employed to encourage even
plating of lithium at section 23 during charge. For example,
although in the embodiment illustrated in FIG. 4 it can be
advantageous to form layer 24 to be substantially non-electrically
conductive overall, one or more layers of the structure can be made
to be electrically conductive to define a current collector
component. For example, in structure 24 one or more of the layers,
for example layer 52 closest to section 23 and electrolyte 60, can
be made somewhat or significantly electrically conductive. In this
way, during charge, even deposition of the first very thin layer of
lithium on the anode can be made to occur essentially evenly across
structure 24. Once a portion of lithium has been deposited, then
the electronic conductivity of lithium itself also facilitates
further even deposition of material 23.
[0072] Structures such as those shown in FIGS. 3 and 4 may be used
with primary or secondary cells. In some cases, a method of
electrical energy storage and use may include alternatively
discharging current from the cell to define an at least partially
discharged device, and at least partially charging said at least
partially discharged device to define an at least partially
recharged device. This discharge and charge may cause the base
electrode material from a working Li layer (e.g., layer 23 of FIG.
4) to be consumed upon discharge to a greater extent than it is
re-plated upon charge, which can cause the base electrode material
to be replenished into the working Li layer, from the base anode
layer (e.g., layer 21 of FIG. 4), across the embedded layer. Such
cells can operate in the presence of an aqueous (e.g., water) or
air electrolyte in electrochemical communication with the anode and
cathode.
[0073] When a rechargeable lithium battery using an aqueous
electrolyte, or other primary or secondary electrochemical device
described herein or useful in connection with components of the
invention, is constructed by those of ordinary skill in the art,
one or many of the features described herein can be employed. For
example, a device can include an electrode stabilization component
22 as shown in FIG. 1. In another arrangement a device can include
a stabilization component 70 as illustrated in FIG. 3. In another
arrangement a multi-layered electrode stabilization structure, such
as described in connection with FIG. 2, can be used as shown in
FIG. 4 in combination with one or more of hydrophobic materials
inhibiting passage of water and/or a basic (pH greater than 7.1, or
higher) aqueous electrolyte. Combinations or one or more of these
structures can result in a significantly robust aqueous-based
lithium rechargeable battery, and the battery may also be compact
and/or light weight (e.g., the total thickness of the layers
between and including the anode and an outer layer may be less than
1 cm, less than 0.5 cm, less than 1 mm, less than 700 microns, less
than 500 microns, less than 300 microns, less than 250 microns,
less than 200 microns, less than 150 microns, less than 100
microns, less than 75 microns, less than 50 microns, or less than
10 microns). As such, the invention enables a method of electrical
energy storage and use including providing an electrochemical cell
comprising an anode with lithium as the active anode material, a
cathode, and an aqueous electrolyte in electrochemical
communication with the anode and cathode, and cycling the cell, by
alternatively discharging and charging the cell, at least n times
wherein, at the end of the nth cycle, the cell exhibits at least
80% of the cell's initial capacity, where n=at least 3, 5, 10, 15,
25, 50, 100, 150, 200, or 250 or more. As noted, the invention can
be used to enhance the lifetime of rechargeable lithium batteries
employing aqueous-based electrolytes. As used herein,
"aqueous-based electrolyte" means an electrolyte including at least
20%, by weight, water, and more typically at least 50%, 70%, 80%,
or 95% or more water by weight. Several additional features are
included in the invention to assist function in a rechargeable
battery useful in an aqueous environment, or an environment exposed
to air. In the case of an aqueous-based electrolyte, in one set of
embodiments the electrolyte is formulated so as to have a pH of at
least 7.1, and in other embodiments at least 7.2, 7.3. 7.4., 7.5,
7.6, 7.7, or 7.8 providing an electrolyte in basic form such as
this inherently significantly reduces the presence of hydrogen ion
which can be destructive if exposed to a lithium or other alkali
metal electrode. In some embodiments, the electrolyte may have a pH
between 7-8, between 8-9, between 9-10, between 10-11, or between
11-12 prior to the first discharge.
[0074] Formulating an electrolyte in basic form can be carried out
by those of ordinary skill in the art, without undue
experimentation, while providing the electrolyte with the ability
to function effectively in the device and not causing inhibitory or
other destructive behavior. Suitable basic species that may be
added to an aqueous-based electrolyte, employed with a lithium
battery, to achieve a basic pH as noted above may depend on, for
example, the specific components of the lithium battery, the
environment of use (e.g., an air/oxygen or water environment), the
method of using the battery (e.g., a primary or secondary battery),
etc. Suitable basic species may also be chosen based on the
basicity (e.g., pH) of the species, the diffusivity of the species,
and/or the likelihood of the species reacting with the electrolyte,
other components in the electrolyte, components of the anode (e.g.,
polymer layers, single ion conductive layers, and anode layers),
and/or the cathode material. Typically, chemical reaction between
the basic species and such components of the battery are avoided.
Accordingly, those of ordinary skill in the art can choose an
appropriate basic species by, e.g., knowing the components of the
battery and the likelihood of reactivity between the species and
the components, and/or by a simple screening test. One simple
screening test may include adding the species to the electrolyte in
the presence of a material component of the cell, e.g., a
single-ion conductive material, and determining whether the species
reacts and/or negatively effects the material. Another simple
screening test may include adding the species to the electrolyte of
the battery in the presence of the battery components,
discharging/charging the battery, and observing whether inhibitory
or other destructive behavior occurs compared to that in a control
system. Other simple tests can be conducted by those of ordinary
skill in the art.
[0075] Species that may be added to an aqueous-based electrolyte,
employed with a lithium battery, to achieve a basic pH as noted
above include bases comprising alkali and alkali earth metals
(Group 1 and 2 metals, respectively), as well as
ammonium-containing species (e.g., ammonium hydroxides, carbonates,
and sulfides). Specific examples of species that can be added to an
aqueous-based electrolyte to achieve a basic pH include, but are
not limited to, ammonia, aniline, methylamine, ethylamine,
pyridine, calcium carbonate, calcium hydroxide, ferrous hydroxide,
potassium acetate, potassium bicarbonate, potassium carbonate,
potassium cyanide, potassium hydroxide, sodium acetate, sodium
benzoate, sodium bicarbonate, sodium carbonate, sodium hydroxide,
sodium metasilicate, sodium sesquicarbonate, sodium phosphate,
sodium hydrogen phosphate, sodium sulfite, sodium cyanide,
trisodium phosphate, magnesium hydroxide, barium hydroxide, calcium
hydroxide, lithium hydroxide, rubidium hydroxide, cesium hydroxide,
and strontium hydroxide. It is routine for those of ordinary skill
in the art to determine the amount of such an additive needed to
create an electrolyte of desired pH.
[0076] In another arrangement suitable for maximizing the
effectiveness of an alkali metal electrode-containing device used
in combination with an aqueous-based electrolyte, especially a
rechargeable battery, the electrode stabilization/protective
component (e.g., as illustrated in FIGS. 1 and 2, and optionally
FIGS. 3 and 4) can be made to be substantially impermeable to
water. This can be done by selecting one or more materials that are
sufficiently hydrophobic or otherwise impede water transport. This
concept will be described, by way of example only, with reference
to FIG. 2. In FIG. 2, one effective device will include a top layer
(layer 56 as illustrated) that is significantly hydrophobic so as
to prevent water passage. In another arrangement, an intermediate
layer (e.g., 44, 52, 42, etc.) can be made sufficiently hydrophobic
to block water passage. In another arrangement, none of the layers
individually is sufficiently hydrophobic or otherwise formulated to
substantially prevent water passage but, together the layers
substantially prevent water passage. For example, each layer, or
some combination or subcombination of layers, can be made somewhat
hydrophobic so that each repels water to some extent. In this
arrangement, the combination of the layers can be formulated and/or
selected to substantially prevent water passage overall. One
measure of hydrophobicity that can be useful in selecting such
materials is contact angle measurements taken between water and a
candidate material. While "hydrophobic" can be considered a
relative term in some cases, a particular degree or amount of
hydrophobicity can be easily selected by those of ordinary skill in
the art, with the aid of knowledge of the characteristics of
particular materials and/or readily-determined contact angle
measurements to select materials for construction of an anode
stabilization structure which, overall, impedes water passage
significantly. "Significantly" in this context, can mean that where
an aqueous electrolyte is used, after 100 cycles of a rechargeable
device employing the stabilization component water will be
completely absent from the electrode under the stabilization
component (the side opposite the electrolyte) or, if present, will
be present in an amount less than 100 parts per million measured to
include all molecular species at that location. In other
embodiments, water will be present in an amount less than 75 ppm,
less than 50, 25, 10, 5, or 2 ppm.
[0077] A variety of materials and arrangements can be used in
individual assemblies described and illustrated herein, or in all
of the assemblies. It is to be understood that where a particular
component or arrangement is described in connection with one
embodiment or figure, that component or arrangement can be used in
connection with any others. One example of such a structure is a
separation layer, e.g., a temporary protective material layer or a
plasma CO.sub.2 treatment layer, positioned between the an anode
layer and a polymer layer or a multi-layered structure. For
example, in the embodiments shown in FIG. 1, layer 30 is a
separation layer. It is to be understood that where a separation
layer 30 is used, the first layer adjacent the separation layer
opposite the electrode is described herein at times to be adjacent
the electrode. This is because the separation layer is optional. In
all instances in which a layer is described as being adjacent, or
immediately adjacent an electrode (for example the polymer layer 40
of FIG. 1), an intervening separation layer can be used but need
not be used. Separation layers may improve the compatibility of the
base electrode material (e.g., lithium) with layers deposited on
top of the electrode. For example, when a single-ion conductive
layer is desired at the lithium interface, it is preferable to
deposit this directly on the lithium surface. However, the
precursors to, or components of, such an interfacial layer may
react with lithium to produce undesirable by-products or result in
undesirable changes in the morphology of the layers. By depositing
a separation layer on the lithium surface prior to depositing the
interfacial layer such as a multi-layer structure 24 (FIG. 2), side
reactions at the lithium surface may be eliminated or significantly
reduced. For example, when an interfacial film of a lithium
phosphorus oxynitride, as described in U.S. Pat. No. 5,314,765 to
Bates, is deposited in a nitrogen atmosphere by sputtering of
Li.sub.3PO.sub.4 onto a lithium surface, the nitrogen gas may react
with lithium to form lithium nitride (LiN.sub.3) at the anode
surface. By depositing a layer of a protective material that can be
"temporary", e.g., copper over the lithium surface, the interfacial
layer may be formed without the formation of lithium nitride. A
"temporary" protective layer is one that ceases to be in existence
or identifiable after some time after construction of the device,
for example after some period of use of the device. For example, a
thin layer of copper 30 positioned over a lithium anode 20
(described in the context of FIG. 1) will diffuse into an alloy
with the anode until, after a particular period of time and/or use
of the device, anode 20 will be primarily lithium, with a trace of
copper, but layer 30 will no longer exist or be identifiable.
[0078] A temporary protective material layer may include a material
that is capable of forming an alloy with lithium metal, or is
capable of diffusing into, dissolving into, and/or blending with
lithium metal, e.g., during electrochemical cycling of the cell
and/or prior to electrochemical cycling of the cell. The temporary
protective material layer can act as a barrier layer to protect the
lithium surface during deposition of other layers, such as during
the deposition of a multi-layered structure on top of the anode.
Further, the temporary protective layer may allow transportation of
the lithium films from one processing station to the next without
undesirable reactions occurring at the lithium surface during
assembly of cells, or for solvent coating of layers onto the
anode.
[0079] The thickness of the temporary protective material layer is
selected to provide the necessary protection to the layer
comprising lithium, for example, during subsequent treatments to
deposit other anode or cell layers. In some embodiments, it is
desirable to keep the layer thickness as thin as possible while
providing the desired degree of protection so as to not add excess
amounts of non-active materials to the cell which would increase
the weight of the cell and reduce its energy density. In one
embodiment, the thickness of the temporary protective layer is
between 5 to 500 nanometers, e.g., between 20 to 200 nanometers,
between 50 to 200 nanometers, or between 100 to 150 nanometers.
[0080] Suitable materials that can be used as temporary protective
material layers include metals such as copper, magnesium, aluminum,
silver, gold, lead, cadmium, bismuth, indium, gallium, germanium,
zinc, tin, and platinum.
[0081] In some cases, protective structure 30 can include plasma
treated layers such as CO.sub.2 or SO.sub.2 induced layers. Plasma
treated layers can allow nearly the entire anode surface area to
participate in the current carrying process. In other words, plasma
treated layers may allow uniform current density across a surface
and decreases the amount of pitting on a surface. In some cases,
these treatments alone routinely increase cycle life by 15% to 35%
because more of the Li is available for use during discharge. The
plasma surface treatments can make more of the Li available to be
cycled by creating a surface that is substantially homogeneous in
topography.
[0082] FIG. 5 illustrates the results of one comparative experiment
showing the benefits of a temporary protective layer 30, which can
be used in combination with any or all other features of the
invention. FIG. 5 shows SEM images of Li anode surfaces after a
10.sup.th discharge. FIGS. 5A-5C show images of a Li anode alone
without plasma treatment through progressive use of the device. The
spots are areas where Li has been corroded from the surface. FIGS.
5D-5F show anode surfaces treated with a layer of LiPON through
progressive use, comparative to FIGS. 5A-5C. With these surfaces,
the Li only corrodes under defects in the LiPON coating. FIGS.
5G-5I show anode surfaces that have been treated with a CO.sub.2
plasma, again through progressive use comparative to that of FIGS.
5A-5C and FIGS. 5D-5F. These images show that a substantial portion
of the anode surface was utilized during discharge, indicating
lower current discharge density across the surface and increased
cycle life.
[0083] Another example of a structure that can be used in
connection with several embodiments of the invention include
single-ion conductive layers (e.g., as part of a multi-layered
structure) that are treated with a transport-inhibiting substance
which can be a polymer or other species such that any nanopores
and/or pinholes of the single-ion conductive layer are at least
partially filled with the polymer. This filling creates an
infiltrated porous barrier (IPBM), which can increase the barrier
properties of the layer by decreasing the rate of transport of
certain species (e.g., electrolyte, water, and oxygen) towards the
anode.
[0084] Advantageously, the filled single-ion conductive layer can
have a combination of low permeability and high flexibility, due to
the resultant network of infiltrating transport-inhibiting
substance. The higher elastic modulus of such a species, when a
polymer is selected, relative to the brittle compounds that may be
used for the single-ion conductive layer can provide flexibility in
the IPBM, as well as a resistance to fracture, that is not possible
with certain single-ion conductive materials. Polymers having
physical characteristics as described elsewhere herein can be used
for such infiltrating species. This flexibility without fracture
may improve adhesion between the infiltrated polymer and the
internal surfaces of the single-ion conductive material is
increased due to the high surface energy of the single-ion
conductive material prior to infiltration.
[0085] In one embodiment, a single-ion conductive layer is
infiltrated with a monomeric precursor of the transport-inhibiting
substance, so that the porous structure is effectively filled with
the monomer, the monomer being driven into the nanoporous regions
of the porous single-ion conductive layer by the high surface
energy present on the single-ion conductive layer's internal
surfaces. The single-ion conductive material may be treated with an
activation process before treatment with the monomer, so that
surface energy within the material becomes unusually high, relative
to that achievable in normal atmospheric processes.
[0086] In some instances, monomer vapor can be condensed onto the
single-ion conductive material layer, whereby it is then able to
wick along the internal surfaces of the single-ion conductive
material layer, until all, or some useful portion of, such
available tortuous by-paths of permeation are filled by the
monomer. A subsequent curing step, either photo-initiated
techniques, plasma treatment, or an electron beam, can then be
introduced for polymerization of the infiltrated monomer. The
particular cure method utilized will depend on the specific choice
of materials and the layer thickness, amongst other variables.
[0087] Suitable material used as the transport-inhibiting substance
includes material known to fully or partially inhibit (or
determined to inhibit through simple screening) transport of a
particular unwanted species through the material. As mentioned,
material may also be selected according to physical properties,
including properties adding flexibility and/or strength to the
overall material with which it is combined. Specific examples of
materials include, as noted, polymers described herein for use as
layers in the multi-layered structure, and/or other polymeric or
other species. Where hydrophobicity is desirably added to the
overall arrangement, one way to do so is to use an infiltrating
transport-inhibiting substance having some degree of hydrophobic
character.
[0088] Formation of IPBM-type structures may be accomplished by a
variety of means; however, in some embodiments, the IPBM is formed
by vacuum vapor deposition methods and apparatus readily available
in prior art manufacturing processes. Accordingly, an IPBM may be
formed utilizing a variety of prior art vapor sources for the IPBM
material. The inorganic vapor source may comprise any appropriate
source of the prior art, including but not limited to sputtering,
evaporation, electron-beam evaporation, chemical vapor deposition
(CVD), plasma-assisted CVD, etc. The monomer vapor source may
similarly be any monomer vapor source of the prior art, including
but not limited to flash evaporation, boat evaporation, Vacuum
Monomer Technique (VMT), polymer multilayer (PML) techniques,
evaporation from a permeable membrane, or any other source found
effective for producing a monomer vapor. For example, the monomer
vapor may be created from various permeable metal frits, as
previously in the art of monomer deposition. Such methods are
taught in U.S. Pat. No. 5,536,323 (Kirlin) and U.S. Pat. No.
5,711,816 (Kirlin), amongst others.
[0089] A separate activation may be utilized in some cases for
providing additional activation energy during or after deposition
of the single-ion conductive material layer. In some cases, such as
in certain types of unbalanced magnetron sputtering, plasma
immersion, or plasma-enhanced CVD, a separate activation source may
not be required, as the sufficient activation is already attained
by the deposition method itself. Alternatively, certain types of
single-ion conductive materials, such as those that provide
catalytic or low work function surfaces, e.g., ZrO.sub.2,
Ta.sub.2O.sub.5, or various oxides and fluorides of Group IA and
Group IIA metals, may provide sufficient activation even in
relatively non-activating deposition processes.
[0090] Not all of the surface area within a single-ion conductive
material layer need be infiltrated by the transport-inhibiting
substance to achieve an effective permeation barrier. Accordingly,
it is not required that all of the pores within the single-ion
conductive material layer be filled. In some cases, less than 10%,
less than 25%, less than 50%, less than 75%, or less than 90%, of
the pores and/or pinholes can be filled with a polymer, e.g., to
achieve decrease in permeation of certain species across the layer.
In some cases, the advantages described above can be obtained so
long as those pores that substantially contribute to permeation are
substantially filled by the polymer.
[0091] Other advantages and methods of forming filled single-ion
conductive layers are discussed in U.S. Patent Application No.
2005/0051763 (Affinito).
[0092] FIG. 6 illustrates a principle behind use of a multi-layer
electrode stabilization component, such as illustrated in FIGS. 2,
4, and 7, with filled nanopores/pinholes and illustrating the
significant barrier to passage of unwanted components from
electrolyte to anode through the electrode stabilization layer. In
the figure, a tortuous pathway represented by arrow 71 is presented
by way of example to show the significant distance, and tortuosity,
through which such a species would need to pass to penetrate the
entire multi-layer arrangement to arrive at the anode. Where
nanopores and pinholes are filled with a penetrating
transport-inhibiting substance such as an inhibiting polymeric
substance, transport is significantly slowed. This, combined with
tortuosity as illustrated, can result in the exponential decrease
in transport of such species and exponential increase in cycle
life, as noted above. It can be seen how increasing the number of
layers, with resultant offset of pinholes existing in
ion-conductive materials, creates this tortuous pathway. Where a
single layer of such material is used, pinholes can be
substantially more easily traversed by unwanted species accessing
the electrode. In certain embodiments, the transport-inhibiting
substance fills essentially all voids including pinholes and
nanopores of the single ion-conducting material, and/or that of the
polymer layers. In other arrangements, only a portion of voids of
one or both are filled. In some cases, the transport-inhibiting
substance is an auxiliary substance, that is, a substance not
native to the single ion-conducting material, and/or that of the
polymer layers. That is, the material may be a species not forming
a portion of one of these components as these components would
otherwise be fabricated and assembled together, but is present only
through an auxiliary process required to fill such voids. In some
cases, the material is not native to either the single-ion
conductive material or the polymeric material.
[0093] In some embodiments, structures include an outer layer,
e.g., a layer that is in contact with the electrolyte of the cell.
This outer layer can be a layer such as stabilization layers 22,
24, 26, etc. as shown in the figures, or can be an auxiliary outer
layer specifically selected to interface directly with the
electrolyte. Where such an auxiliary outer layer is used, it may be
selected to be significantly hydrophobic when used in connection
with an aqueous electrolyte and a rechargeable lithium battery.
Outer layers may be selected for properties such as Li-ion
conduction, electron conduction, protection of underlying layers
which may be unstable to components present in the electrolyte,
nonporous to prevent penetration by electrolyte solvents,
compatible with electrolyte and the underlying layers, and flexible
enough to accommodate for volume changes in the layers observed
during discharge and charge. The outer layer should further be
stable and preferably insoluble in the electrolyte.
[0094] Examples of suitable outer layers include, but are not
limited to, organic or inorganic solid polymer electrolytes,
electrically and ionically conducting polymers, and metals with
certain lithium solubility properties. In one embodiment, the
polymer of the outer layer is selected from the group consisting of
electrically conductive polymers, ionically conductive polymers,
sulfonated polymers, and hydrocarbon polymers. Further examples of
suitable polymers for use in the outer layer of the present
invention are those described in U.S. Pat. No. 6,183,901 to Ying et
al.
[0095] As noted, structures may further comprise a substrate, on a
surface of an anode layer, e.g., on a side opposite to that of a
multi-layer structure. Substrates are useful as a support on which
to deposit the first layer comprising the base electrode material,
and may provide additional stability for handling of thin lithium
film anodes during cell fabrication. Further, in the case of
conductive substrates, these may also function as a current
collector useful in efficiently collecting the electrical current
generated throughout the anode and in providing an efficient
surface for attachment of the electrical contacts leading to the
external circuit. A wide range of substrates are known in the art
of anodes. Suitable substrates include, but are not limited to,
those including metal foils, polymer films, metallized polymer
films, electrically conductive polymer films, polymer films having
an electrically conductive coating, electrically conductive polymer
films having an electrically conductive metal coating, and polymer
films having conductive particles dispersed therein.
[0096] FIG. 7 shows an example of a structure including several
embodiments described herein. As illustrated in the embodiment
shown in FIG. 7, structure 14 can include a substrate 96 and a
layer 20 (e.g., based on or essentially completely comprising
lithium metal). A separation layer 30, which may include a plasma
treated layer or a temporary metal layer, may be formed on top of
base anode layer 21. The structure may include a second lithium
layer 23, and an embedded layer 72 comprising, e.g., alternating
polymer layers 40 and 42, and single-ion conductive layers 50 and
52. In some embodiments, the single-ion conductive material layers
may comprise, or consist essentially of, a metal. The single-ion
conductive layers material may be an IPBM-type structure, e.g., a
layer in which the nanopores/pinholes are filled with a suitable
polymer to decrease permeation of the layer. A second separation
layer 32 may be disposed on top of the second lithium layer 22.
Multi-layered structure 28 can include four alternating layers of
polymer (e.g., layers 43, 44, 45, and 46) and single-ion conductive
materials (e.g., layers 53, 54, 55, and 56). Of course, greater
than four polymer/single ion conductive layers can be included. The
structure can also include a current collector 81, and an outer
layer 90 may be positioned between the anode layer 20 and
electrolyte 60 of the cell. In some cases, the layers that protect
the anode, e.g., layers between and including separation layer 30
and outer layer 90, can have a total overall thickness of, e.g.,
less than 5 mm, less than 3 mm, less than 2 mm, less than 1 mm,
less than 700 microns, less than 500 microns, less than 400
microns, less than 300 microns, less than 250 microns, less than
200 microns, less than 150 microns, less than 100 microns, less
than 75 microns, or less than 50 microns, less than 25 microns, or
less than 10 microns.
[0097] Advantageously, batteries of the invention can be compact,
light weight and can have high energy density. The layers of a cell
between and including anode 20 and outer layer 90 may have a total
thickness of less than 2 cm, less than 1.5 cm, less than 1 cm, less
than 0.7 cm, less than 0.5 cm, less than 0.3 cm, less than 1 mm,
less than 700 microns, less than 500 microns, less than 400
microns, less than 300 microns, less than 250 microns, less than
200 microns, less than 150 microns, less than 100 microns, less
than 75 microns, or less than 50 microns, less than 25 microns, or
less than 10 microns, e.g., depending on the particular application
of the cell. Embodiments such as structures 14 may be suitable for
use with electrolytes such as aqueous solvents, e.g., water, and
can operate as either primary or secondary cells.
[0098] Suitable cathode active materials for use in the cathode of
the electrochemical cells of the invention include, but are not
limited to, electroactive transition metal chalcogenides,
electroactive conductive polymers, and electroactive
sulfur-containing materials, and combinations thereof. As used
herein, the term "chalcogenides" pertains to compounds that contain
one or more of the elements of oxygen, sulfur, and selenium.
Examples of suitable transition metal chalcogenides include, but
are not limited to, the electroactive oxides, sulfides, and
selenides of transition metals selected from the group consisting
of Mn, V, Cr, Ti, Fe, Co, Ni, Cu, Y, Zr, Nb, Mo, Ru, Rh, Pd, Ag,
Hf, Ta, W, Re, Os, and Ir. In one embodiment, the transition metal
chalcogenide is selected from the group consisting of the
electroactive oxides of nickel, manganese, cobalt, and vanadium,
and the electroactive sulfides of iron. In one embodiment, the
cathode active layer comprises an electroactive conductive polymer.
Examples of suitable electroactive conductive polymers include, but
are not limited to, electroactive and electronically conductive
polymers selected from the group consisting of polypyrroles,
polyanilines, polyphenylenes, polythiophenes, and polyacetylenes.
Preferred conductive polymers are polypyrroles, polyanilines, and
polyacetylenes.
[0099] "Electroactive sulfur-containing materials," as used herein,
relates to cathode active materials which comprise the element
sulfur in any form, wherein the electrochemical activity involves
the breaking or forming of sulfur-sulfur covalent bonds. Suitable
electroactive sulfur-containing materials, include, but are not
limited to, elemental sulfur and organic materials comprising
sulfur atoms and carbon atoms, which may or may not be polymeric.
Suitable organic materials include those further comprising
heteroatoms, conductive polymer segments, composites, and
conductive polymers.
[0100] In some embodiments involving Li/S systems, the
sulfur-containing material, in its oxidized form, comprises a
polysulfide moiety, S.sub.m, selected from the group consisting of
covalent --S.sub.m- moieties, ionic --S.sub.m.sup.- moieties, and
ionic S.sub.m.sup.2- moieties, wherein m is an integer equal to or
greater than 3. In one embodiment, m of the polysulfide moiety,
S.sub.m, of the sulfur-containing polymer is an integer equal to or
greater than 6. In another embodiment, m of the polysulfide moiety,
S.sub.m, of the sulfur-containing polymer is an integer equal to or
greater than 8. In another embodiment, the sulfur-containing
material is a sulfur-containing polymer. In another embodiment, the
sulfur-containing polymer has a polymer backbone chain and the
polysulfide moiety, S.sub.m, is covalently bonded by one or both of
its terminal sulfur atoms as a side group to the polymer backbone
chain. In yet another embodiment, the sulfur-containing polymer has
a polymer backbone chain and the polysulfide moiety, S.sub.m, is
incorporated into the polymer backbone chain by covalent bonding of
the terminal sulfur atoms of the polysulfide moiety.
[0101] In one embodiment, the electroactive sulfur-containing
material comprises greater than 50% by weight of sulfur. In another
embodiment, the electroactive sulfur-containing material comprises
greater than 75% by weight of sulfur. In yet another embodiment,
the electroactive sulfur-containing material comprises greater than
90% by weight of sulfur.
[0102] The nature of the electroactive sulfur-containing materials
useful in the practice of this invention may vary widely, as known
in the art. In one embodiment, the electroactive sulfur-containing
material comprises elemental sulfur. In another embodiment, the
electroactive sulfur-containing material comprises a mixture of
elemental sulfur and a sulfur-containing polymer.
[0103] Examples of sulfur-containing polymers include those
described in: U.S. Pat. Nos. 5,601,947 and 5,690,702 to Skotheim et
al.; U.S. Pat. Nos. 5,529,860 and 6,117,590 to Skotheim et al.; and
U.S. patent application Ser. No. 08/995,122 now U.S. Pat. No.
6,201,100 issued Mar. 13, 2001, to Gorkovenko et al. of the common
assignee and PCT Publication No. WO 99/33130. Other suitable
electroactive sulfur-containing materials comprising polysulfide
linkages are described in U.S. Pat. No. 5,441,831 to Skotheim et
al.; U.S. Pat. No. 4,664,991 to Perichaud et al., and in U.S. Pat.
Nos. 5,723,230, 5,783,330, 5,792,575 and 5,882,819 to Naoi et al.
Still further examples of electroactive sulfur-containing materials
include those comprising disulfide groups as described, for example
in, U.S. Pat. No. 4,739,018 to Armand et al.; U.S. Pat. Nos.
4,833,048 and 4,917,974, both to De Jonghe et al.; U.S. Pat. Nos.
5,162,175 and 5,516,598, both to Visco et al.; and U.S. Pat. No.
5,324,599 to Oyama et al.
[0104] Cathodes may further comprise one or more conductive fillers
to provide enhanced electronic conductivity. Examples of conductive
fillers include, but are not limited to, those including conductive
carbons, graphites, activated carbon fibers, non-activated carbon
nanofibers, metal flakes, metal powders, metal fibers, carbon
fabrics, metal mesh, and electrically conductive polymers. The
amount of conductive filler, if present, may be present in the
range of 2 to 30% by weight of the cathode active layer. The
cathodes may also further comprise other additives including, but
not limited to, metal oxides, aluminas, silicas, and transition
metal chalcogenides.
[0105] Cathodes may also comprise a binder. The choice of binder
material may vary widely so long as it is inert with respect to the
other materials in the cathode. Useful binders are those materials,
usually polymeric, that allow for ease of processing of battery
electrode composites and are generally known to those skilled in
the art of electrode fabrication. Examples of useful binders
include polytetrafluoroethylenes (Teflon), polyvinylidene fluorides
(PVF.sub.2 or PVDF), ethylene-propylene-diene (EPDM) rubbers,
polyethylene oxides (PEO), UV curable acrylates, UV curable
methacrylates, and heat curable divinyl ethers, and the like. The
amount of binder, if present, may be present in the range of 2 to
30% by weight of the cathode active layer.
[0106] The electrolytes used in electrochemical or battery cells
can function as a medium for the storage and transport of ions, and
in the special case of solid electrolytes and gel electrolytes,
these materials may additionally function as a separator between
the anode and the cathode. As noted, in one set of embodiments an
aqueous-based electrolyte is used. Any liquid, solid, or gel
material capable of storing and transporting ions may be used, so
long as the material is electrochemically and chemically unreactive
with respect to the anode and the cathode, and the material
facilitates the transport of lithium ions between the anode and the
cathode. The electrolyte may be electronically non-conductive to
prevent short circuiting between the anode and the cathode.
[0107] The electrolyte can comprise one or more ionic electrolyte
salts to provide ionic conductivity and one or more liquid
electrolyte solvents, gel polymer materials, or polymer materials.
Suitable non-aqueous electrolytes may include organic electrolytes
comprising one or more materials selected from the group consisting
of liquid electrolytes, gel polymer electrolytes, and solid polymer
electrolytes. Examples of non-aqueous electrolytes for lithium
batteries are described by Dominey in Lithium Batteries, New
Materials, Developments and Perspectives, Chapter 4, pp. 137-165,
Elsevier, Amsterdam (1994). Examples of gel polymer electrolytes
and solid polymer electrolytes are described by Alamgir et al. in
Lithium Batteries, New Materials, Developments and Perspectives,
Chapter 3, pp. 93-136, Elsevier, Amsterdam (1994).
[0108] Examples of useful non-aqueous liquid electrolyte solvents
include, but are not limited to, non-aqueous organic solvents, such
as, for example, N-methyl acetamide, acetonitrile, acetals, ketals,
esters, carbonates, sulfones, sulfites, sulfolanes, aliphatic
ethers, cyclic ethers, glymes, polyethers, phosphate esters,
siloxanes, dioxolanes, N-alkylpyrrolidones, substituted forms of
the foregoing, and blends thereof. Fluorinated derivatives of the
foregoing are also useful as liquid electrolyte solvents.
[0109] In some cases, aqueous solvents can be used as electrolytes
for lithium cells. Aqueous solvents can include water, which can
contain other components such as ionic salts. As noted above, in
some embodiments, the electrolyte can include species such as
lithium hydroxide, or other species rendering the electrolyte
basic, so as to reduce the concentration of hydrogen ions in the
electrolyte.
[0110] Liquid electrolyte solvents can also be useful as
plasticizers for gel polymer electrolytes. Examples of useful gel
polymer electrolytes include, but are not limited to, those
comprising one or more polymers selected from the group consisting
of polyethylene oxides, polypropylene oxides, polyacrylonitriles,
polysiloxanes, polyimides, polyphosphazenes, polyethers, sulfonated
polyimides, perfluorinated membranes (NAFION resins), polydivinyl
polyethylene glycols, polyethylene glycol diacrylates, polyethylene
glycol dimethacrylates, derivatives of the foregoing, copolymers of
the foregoing, crosslinked and network structures of the foregoing,
and blends of the foregoing, and optionally, one or more
plasticizers.
[0111] Examples of useful solid polymer electrolytes include, but
are not limited to, those comprising one or more polymers selected
from the group consisting of polyethers, polyethylene oxides,
polypropylene oxides, polyimides, polyphosphazenes,
polyacrylonitriles, polysiloxanes, derivatives of the foregoing,
copolymers of the foregoing, crosslinked and network structures of
the foregoing, and blends of the foregoing.
[0112] In addition to electrolyte solvents, gelling agents, and
polymers as known in the art for forming electrolytes, the
electrolyte may further comprise one or more ionic electrolyte
salts, also as known in the art, to increase the ionic
conductivity.
[0113] Examples of ionic electrolyte salts for use in the
electrolytes of the present invention include, but are not limited
to, LiSCN, LiBr, LiI, LiClO.sub.4, LiAsF.sub.6, LiSO.sub.3CF.sub.3,
LiSO.sub.3CH.sub.3, LiBF.sub.4, LiB(Ph).sub.4, LiPF.sub.6,
LiC(SO.sub.2CF.sub.3).sub.3, and LiN(SO.sub.2CF.sub.3).sub.2. Other
electrolyte salts that may be useful include lithium polysulfides
(Li.sub.2S.sub.x), and lithium salts of organic ionic polysulfides
(LiS.sub.xR).sub.n, where x is an integer from 1 to 20, n is an
integer from 1 to 3, and R is an organic group, and those disclosed
in U.S. Pat. No. 5,538,812 to Lee et al.
[0114] In some embodiments, electrochemical cells may further
comprise a separator interposed between the cathode and anode. The
separator may be a solid non-conductive or insulative material
which separates or insulates the anode and the cathode from each
other preventing short circuiting, and which permits the transport
of ions between the anode and the cathode.
[0115] The pores of the separator may be partially or substantially
filled with electrolyte. Separators may be supplied as porous free
standing films which are interleaved with the anodes and the
cathodes during the fabrication of cells. Alternatively, the porous
separator layer may be applied directly to the surface of one of
the electrodes, for example, as described in PCT Publication No. WO
99/33125 to Carlson et al. and in U.S. Pat. No. 5,194,341 to Bagley
et al.
[0116] A variety of separator materials are known in the art.
Examples of suitable solid porous separator materials include, but
are not limited to, polyolefins, such as, for example,
polyethylenes and polypropylenes, glass fiber filter papers, and
ceramic materials. Further examples of separators and separator
materials suitable for use in this invention are those comprising a
microporous xerogel layer, for example, a microporous
pseudo-boehmite layer, which may be provided either as a free
standing film or by a direct coating application on one of the
electrodes, as described in U.S. patent application Ser. Nos.
08/995,089 and 09/215,112 by Carlson et al. of the common assignee.
Solid electrolytes and gel electrolytes may also function as a
separator in addition to their electrolyte function.
[0117] As noted above, a variety of ion-conductive species, and
polymeric species, are useful in connection with the invention. In
some cases, ion conductive species that are also electrically
conductive are employed. In other cases, ion conductor species that
are substantially non-electrically conductive are employed.
[0118] Examples of ion conductor species, including
single-ion-conductive species suitable for use in the invention,
which are also substantially electrically conductive, include
lithium alloys such as lithium combined with Group 14 and Group 15
metals (e.g., Ge, Sn, Pb, As, Sb, Bi). Polymers that are conductive
to single ions that are also substantially electrically conductive
include electrically conductive polymers (also known as electronic
polymers or conductive polymers) that are doped with lithium salts
(e.g., LiSCN, LiBr, LiI, LiClO.sub.4, LiAsF.sub.6,
LiSO.sub.3CF.sub.3, LiSO.sub.3CH.sub.3, LiBF.sub.4, LiB(Ph).sub.4,
LiPF.sub.6, LiC(SO.sub.2CF.sub.3).sub.3, and
LiN(SO.sub.2CF.sub.3).sub.2). Conductive polymers are known in the
art; examples of such polymers include, but are not limited to,
poly(acetylene)s, poly(pyrrole)s, poly(thiophene)s, poly(aniline)s,
poly(fluorene)s, polynaphthalenes, poly(p-phenylene sulfide), and
poly(para-phenylene vinylene)s. Electrically-conductive additives
may also be added to polymers to form electrically-conductive
polymers. Certain electrically conductive materials may have a
conductivity of, e.g., greater than 10.sup.-2 S/cm, greater than
10.sup.-1 S/cm, greater than 1 S/cm, greater than 10.sup.1 S/cm,
greater than 10.sup.2 S/cm, greater than 10.sup.3 S/cm, greater
than 10.sup.4 S/cm, or greater than 10.sup.5 S/cm. Examples of
ion-conductive species that are substantially non-electrically
conductive include non-electrically conductive materials (e.g.,
electrically insulating materials) that are doped with lithium
salts. E.g., acrylate, polyethyleneoxide, silicones,
polyvinylchlorides, and other insulating polymers that are doped
with lithium salts can be ion-conductive but substantially
non-electrically conductive. In some embodiments, single-ion
conductive materials can also include non-polymeric materials.
Certain non-electrically conductive materials may have a
resistivity of, e.g., greater than 10.sup.3 ohm-cm, greater than
10.sup.4 ohm-cm, greater than 10.sup.5 ohm-cm, greater than
10.sup.6 ohm-cm, greater than 10.sup.7 ohm-cm, or greater than
10.sup.8 ohm-cm. Those of ordinary skill in the art can select
single ion conductive species that are both substantially
electrically conductive and substantially non-electrically
conductive without undue experimentation, and can employ a simple
screening test to select from candidate materials. The simple
screening test involves positioning a material as a separator in an
electrochemical cell which, to function, requires passage of both
an ionic species and electrons across the material. This is a
simple test to employ. If the material is substantially ionically
conductive and electronically conductive in this test, then
resistance or resistivity across the material will be low. Other
simple tests can be conducted by those of ordinary skill in the
art.
[0119] The invention also employs polymeric materials, some of
which are ionically-conductive and some of which are electronically
conductive. As is the case for single ion conductive materials that
are or are not electronically conductive, those of ordinary skill
in the art can readily select, or formulate, such polymeric
materials. These polymeric materials also can be selected or
formulated to have physical/mechanical characteristics as described
above by, for example, tailoring the amounts of components of
polymer blends, adjusting the degree of cross-linking (if any),
etc. Simple screening tests such as those described above can be
used to select polymers that have the appropriate ionic and/or
electronic properties.
[0120] Suitable polymer layers for use in a multi-layered structure
include polymers that are highly conductive towards lithium and
minimally conductive towards electrons include, for example,
ionically conductive polymers, sulfonated polymers, and hydrocarbon
polymers. The selection of the polymer will be dependent upon a
number of factors including the properties of electrolyte and
cathode used in the cell. Suitable ionically conductive polymers
include, e.g., ionically conductive polymers known to be useful in
solid polymer electrolytes and gel polymer electrolytes for lithium
electrochemical cells, such as, for example, polyethylene oxides.
Suitable sulfonated polymers include, e.g., sulfonated siloxane
polymers, sulfonated polystyrene-ethylene-butylene polymers, and
sulfonated polystyrene polymers. Suitable hydrocarbon polymers
include, e.g., ethylene-propylene polymers, polystyrene polymers,
and the like.
[0121] Polymer layers of a multi-layered structure can also include
crosslinked polymer materials formed from the polymerization of
monomers such as alkyl acrylates, glycol acrylates, polyglycol
acrylates, polyglycol vinyl ethers, polyglycol divinyl ethers, and
those described in U.S. Pat. No. 6,183.901 to Ying et al. of the
common assignee for protective coating layers for separator layers.
For example, one such crosslinked polymer material is polydivinyl
poly(ethylene glycol). The crosslinked polymer materials may
further comprise salts, for example, lithium salts, to enhance
ionic conductivity. In one embodiment, the polymer layer of the
multi-layered structure comprises a crosslinked polymer.
[0122] Other classes polymers that may be suitable for use in a
polymer layer include, but are not limited to, polyamines (e.g.,
poly(ethylene imine) and polypropylene imine (PPI)); polyamides
(e.g., polyamide (Nylon), poly(c-caprolactam) (Nylon 6),
poly(hexamethylene adipamide) (Nylon 66)), polyimides (e.g.,
polyimide, polynitrile, and poly(pyromellitimide-1,4-diphenyl
ether) (Kapton)); vinyl polymers (e.g., polyacrylamide,
poly(2-vinyl pyridine), poly(N-vinylpyrrolidone),
poly(methylcyanoacrylate), poly(ethylcyanoacrylate),
poly(butylcyanoacrylate), poly(isobutylcyanoacrylate), poly(vinyl
acetate), poly (vinyl alcohol), poly(vinyl chloride), poly(vinyl
fluoride), poly(2-vinyl pyridine), vinyl polymer,
polychlorotrifluoro ethylene, and poly(isohexylcynaoacrylate));
polyacetals; polyolefins (e.g., poly(butene-1), poly(n-pentene-2),
polypropylene, polytetrafluoroethylene); polyesters (e.g.,
polycarbonate, polybutylene terephthalate, polyhydroxybutyrate);
polyethers (poly(ethylene oxide) (PEO), poly(propylene oxide)
(PPO), poly(tetramethylene oxide) (PTMO)); vinylidene polymers
(e.g., polyisobutylene, poly(methyl styrene),
poly(methylmethacrylate) (PMMA), poly(vinylidene chloride), and
poly(vinylidene fluoride)); polyaramides (e.g.,
poly(imino-1,3-phenylene iminoisophthaloyl) and
poly(imino-1,4-phenylene iminoterephthaloyl)); polyheteroaromatic
compounds (e.g., polybenzimidazole (PBI), polybenzobisoxazole (PBO)
and polybenzobisthiazole (PBT)); polyheterocyclic compounds (e.g.,
polypyrrole); polyurethanes; phenolic polymers (e.g.,
phenol-formaldehyde); polyalkynes (e.g., polyacetylene); polydienes
(e.g., 1,2-polybutadiene, cis or trans-1,4-polybutadiene);
polysiloxanes (e.g., poly(dimethylsiloxane) (PDMS),
poly(diethylsiloxane) (PDES), polydiphenylsiloxane (PDPS), and
polymethylphenylsiloxane (PMPS)); and inorganic polymers (e.g.,
polyphosphazene, polyphosphonate, polysilanes, polysilazanes). The
mechanical and electronic properties (e.g., conductivity,
resistivity) of these polymers are known. Accordingly, those of
ordinary skill in the art can choose suitable polymers for use in
lithium batteries, e.g., based on their mechanical and/or
electronic properties (e.g., ionic and/or electronic conductivity),
and/or can modify such polymers to be ionically conducting (e.g.,
conductive towards single ions) and/or electronically conducting
based on knowledge in the art, in combination with the description
herein. For example, the polymer materials listed above may further
comprise salts, for example, lithium salts (e.g., LiSCN, LiBr, LiI,
LiClO.sub.4, LiAsF.sub.6, LiSO.sub.3CF.sub.3, LiSO.sub.3CH.sub.3,
LiBF.sub.4, LiB(Ph).sub.4, LiPF.sub.6, LiC(SO.sub.2CF.sub.3).sub.3,
and LiN(SO.sub.2CF.sub.3).sub.2), to enhance ionic
conductivity.
[0123] The figures that accompany this disclosure are schematic
only, and illustrate a substantially flat battery arrangement. It
is to be understood that any electrochemical cell arrangement can
be constructed, employing the principles of the present invention,
in any configuration. For example, with reference to FIG. 1, anode
20 may be covered on the side opposite the side at which components
30, 40, and 50 are illustrated with a similar or identical set of
components 30, 40, and 50. In this arrangement, a substantially
mirror-image structure is created with a mirror plane passing
through anode 20. This would be the case, for example, in a
"rolled" battery configuration in which a layer of anode 20 is
surrounded on each side by structures 30, 40, and 50 (or, in
alternative arrangements layered structures illustrated in other
figures herein). On the outside of each protective structure of the
anode an electrolyte is provided and, opposite the electrolyte, a
cathode. In a rolled arrangement, or other arrangement including
multiple layers of alternating anode and cathode functionality, the
structure involves anode, electrolyte, cathode, electrolyte, anode
. . . , where each anode can include anode stabilization structures
as described in any part of this disclosure. Of course, at the
outer boundaries of such an assembly, a "terminal" anode or cathode
will be present. Circuitry to interconnect such a layered or rolled
structure is well-known in the art.
[0124] The following examples are intended to illustrate certain
embodiments of the present invention, but are not to be construed
as limiting and do not exemplify the full scope of the
invention.
EXAMPLE 1
Fabrication and Characterization of Lamanode Structures
[0125] Lamanode structures, e.g., structures including a first and
second layers of Li separated by an embedded layer that is
conductive to Li ions, but substantially non-conductive to
electrons, were fabricated by thermal evaporation (vacuum
deposition) of Li on a PET substrate in two layers of Li with
different thickness. The two layers of Li were separated by an
embedded layer of a low-conductive material, e.g., LiPON, Li.sub.3N
or etc. The ratio of the thickness of top and bottom Li layers was
calculated based on a required DoD (depth of discharge) of the
first discharge and was in the range between 0.2 to 0.4. A layer of
about 0.01 to 1 micron LiPON was deposited on top of the bottom
thicker Li layer by rf magnetron spattering from a Li.sub.3PO.sub.4
target in an N.sub.2 atmosphere. A thinner Li layer, e.g., 5
microns, was thermally evaporated on top of the embedded layer.
[0126] The top (thinner) Li layer interfacing the electrolyte was
dissolved at the first discharge. During the next charge, Li was
deposited on the surface of the low-conductive LiPON embedded
layer. During the second discharge, the Li deposit was dissolved to
an extent depending on its cycling efficiency. The Li cycling
efficiency(Eff) is defined by equation (1)
E.sub.eff=Q.sub.a/Q.sub.c (1), where Q.sub.c is the amount of Li
deposit in Ah and Q.sub.a is the amount of dissolved Li in Ah. At a
Li efficiency less than 1, an extra amount of Li was dissolved from
the bulk to complete a 100% cycle. E.sub.eff for a practical system
is typically higher than 0.98. Therefore, during the second
discharge, a negligible amount of Li compared to the total cathode
charge was transferring from the bulk Li through the embedded
layer(s) to the electrolyte and the cathode. This amount, 100 times
smaller than the amount of Li fluxing during the first anodic
dissolution of Li and cathode lithiation, practically does not
affect the surface morphology of the bottom layer of Li and the
adjusted protective layer. The same scenario repeats with any
subsequent 100% cycle to the cell end of life. As fewer defects,
cracks and pinholes are formed on the Li and the adjusted embedded
layer surfaces, the Li cycling efficiency increases and the cycle
life is longer. Such a laminode can be built in a cell along with a
cathode, e.g., having 60 to 75% sulfur and an electrolyte
compatible with the sulfur chemistry.
[0127] In one embodiment, small prismatic cells including working
and counter electrodes with a geometric surface of 30 cm.sup.2 and
a polyethylene "Tonen" separator with a thickness of 16 microns
between were sealed in an aluminized plastic polyethylene bag of
"Sealrite". A solution of a mixture of ethers and Li amide salt was
added in the bag to serve as an electrolyte. Two types of cells
were built: [0128] A) Li working electrode with a thickness about
25 microns made by thermal evaporation of Li on 23 um PET called
for simplicity. This single-layered electrode was used as a
control. [0129] B) Li working electrode with approximately the same
thickness including a three layered structure, e.g., a laminode.
The laminode was made by: [0130] i) 20 micron thermal evaporated Li
on PET, [0131] ii) 0.075 micron of LiPON made by rf magnetron
spattered from a Li.sub.3PO.sub.4 target in an N.sub.2 atmosphere
on the top of the 20 micron Li; and [0132] iii) 5 micron thermal
evaporated Li on top of the layer of LiPON.
[0133] Both cell designs used a counter electrode of 25 micron
thermal evaporated Li on 23 micron PET. The cells were discharged
using the same conditions of a current of 0.2 mA/cm.sup.2 and a 20%
DoD of Li. After the discharge, the cells were opened in a glove
box and the working electrode was studied by SEM.
[0134] The results from these experiments are shown in FIG. 8. FIG.
8A shows a SEM image of the control, and FIG. 8B shows the laminode
structure. FIG. 8C shows a 5000 times magnification of the
structure shown in FIG. 8B after the removal of the top Li layer.
It can be observed from the SEM pictures that the laminode
structure is substantially free of any defects such as cracks and
pinholes. The single layered Li surface control, however, is
strongly affected under the conditions of the first discharge.
[0135] This example shows that a laminode structure including a
first and second layers of Li separated by an embedded layer that
is conductive to Li ions, but substantially non-conductive to
electrons, can increase the desired properties of an
electrochemical cell.
EXAMPLE 2
Cycle Lives of Lamanode Structures
[0136] This example shows that the Li cycling efficiency increases
and the cycle life is longer for cells including laminode
structures compared to cells having single layers of base electrode
materials.
[0137] To fabricate control cells, prismatic cells with thermal
evaporated Li on one side of 23 micron thickness of PET, Separator
Tonen and a cathode containing 65% S coated on one side of a Rexam
Al foil were sealed in a bag of Sealright. A mixture of ethers and
Li imide salt was used as an electrolyte. The working surface of
the anode was 400 cm.sup.2. The cells were tasted for cycle life
performance at a discharge current of 200 mA to a cut-off of 1.8 V,
and charge current of 0.1 A for 4 hours. Cycling results obtained
from three control cells were obtained.
[0138] The same cell design as described above was built but with a
first laminode anode structure (or "sandwich anode") instead of a
single-layered anode. The first laminode structure included a 20
micron thick thermal evaporated Li deposited on 23 microns of PET.
A layer of 0.02 micron of LiPON was rf magnetron sputtered from a
Li.sub.3PO.sub.4 target in an N.sub.2 atmosphere on top of the 20
micron thick Li, and 5 microns of Li was thermally evaporated on
top of the embedded LiPON layer. The same test regime as for the
control cells was applied for these cells.
[0139] The average FoM (Li cycling efficiency) of the controls was
compared to that of the first laminode-containing cells, with the
result that a significant improvement in the cycle life of the
cells was realized.
[0140] Similar cells as those above were built and tested under the
same conditions using a second laminode structure, including a 20
micron thick thermally evaporated Li layer, a 0.075 micron thick
LiPON layer, and a 5 micron thermally evaporated Li layer.
[0141] Comparing the FoM obtained from the second laminode
structure with that of the control, a significant improvement in
the cycle life of the laminode structures compared to the control
anode was observed.
[0142] This example shows that the Li cycling efficiency increases
and the cycle life is longer for cells including laminode
structures compared to cells having single layers of base electrode
materials.
EXAMPLE 3
Effects of Different Types of Anode Protection on Discharge
Capacity
[0143] This example shows effects of different types of anode
protection on discharge capacity of a cell.
[0144] The control used in these experiments included a
VDLi/CO.sub.2 structure, equivalent to a Li foil. A first test
structure included a VDLi/CO.sub.2/polymer (1500-2500 Angstroms)
structure. A second test structure included a VDLi/CO.sub.2/polymer
(1500-2500 Angstroms) structure. A third test structure included a
laminode (Sandwich anode) of VDLi/LiPON/VDLi/CO.sub.2/SPE. In this
particular experiment, each of the cells were cycled several times,
and an improvement of 30-40% in cycle life was obtained when the
cell included a polymer layer compared to a cell without a polymer
layer. A significant improvement in cycle life was obtained when a
cell included an embedded layer of LiPON compared to a cell without
an embedded layer. A cell that included a laminode structure having
an embedded layer and a polymer layer, e.g., a
VDLi/LiPON/VDLi/CO2/SPE cell, had a significant improvement in
cycle life compared to a cell having single-layered anode, e.g.,
VDLi/CO.sub.2. In other embodiments, the degree of improvement in
life-cycle can vary depending on, for example, the number of
polymer layers, multi-layered structures, and embedded layers that
make up the cell, and the thicknesses and materials used to form
such structures.
[0145] This example shows that electrochemical cells including
embedded and polymer layers have increased cycle lives compared to
cells without such structures.
[0146] While several embodiments of the present invention have been
described and illustrated herein, those of ordinary skill in the
art will readily envision a variety of other means and/or
structures for performing the functions and/or obtaining the
results and/or one or more of the advantages described herein, and
each of such variations and/or modifications is deemed to be within
the scope of the present invention. More generally, those skilled
in the art will readily appreciate that all parameters, dimensions,
materials, and configurations described herein are meant to be
exemplary and that the actual parameters, dimensions, materials,
and/or configurations will depend upon the specific application or
applications for which the teachings of the present invention
is/are used. Those skilled in the art will recognize, or be able to
ascertain using no more than routine experimentation, many
equivalents to the specific embodiments of the invention described
herein. It is, therefore, to be understood that the foregoing
embodiments are presented by way of example only and that, within
the scope of the appended claims and equivalents thereto, the
invention may be practiced otherwise than as specifically described
and claimed. The present invention is directed to each individual
feature, system, article, material, kit, and/or method described
herein. In addition, any combination of two or more such features,
systems, articles, materials, kits, and/or methods, if such
features, systems, articles, materials, kits, and/or methods are
not mutually inconsistent, is included within the scope of the
present invention.
[0147] All definitions, as defined and used herein, should be
understood to control over dictionary definitions, definitions in
documents incorporated by reference, and/or ordinary meanings of
the defined terms.
[0148] The indefinite articles "a" and "an," as used herein in the
specification and in the claims, unless clearly indicated to the
contrary, should be understood to mean "at least one."
[0149] The phrase "and/or," as used herein in the specification and
in the claims, should be understood to mean "either or both" of the
elements so conjoined, i.e., elements that are conjunctively
present in some cases and disjunctively present in other cases.
[0150] Multiple elements listed with "and/or" should be construed
in the same fashion, i.e., "one or more" of the elements so
conjoined. Other elements may optionally be present other than the
elements specifically identified by the "and/or" clause, whether
related or unrelated to those elements specifically identified.
Thus, as a non-limiting example, a reference to "A and/or B", when
used in conjunction with open-ended language such as "comprising"
can refer, in one embodiment, to A only (optionally including
elements other than B); in another embodiment, to B only
(optionally including elements other than A); in yet another
embodiment, to both A and B (optionally including other elements);
etc.
[0151] As used herein in the specification and in the claims, "or"
should be understood to have the same meaning as "and/or" as
defined above. For example, when separating items in a list, "or"
or "and/or" shall be interpreted as being inclusive, i.e., the
inclusion of at least one, but also including more than one, of a
number or list of elements, and, optionally, additional unlisted
items. Only terms clearly indicated to the contrary, such as "only
one of" or "exactly one of," or, when used in the claims,
"consisting of," will refer to the inclusion of exactly one element
of a number or list of elements. In general, the term "or" as used
herein shall only be interpreted as indicating exclusive
alternatives (i.e. "one or the other but not both") when preceded
by terms of exclusivity, such as "either," "one of," "only one of,"
or "exactly one of." "Consisting essentially of", when used in the
claims, shall have its ordinary meaning as used in the field of
patent law.
[0152] As used herein in the specification and in the claims, the
phrase "at least one," in reference to a list of one or more
elements, should be understood to mean at least one element
selected from any one or more of the elements in the list of
elements, but not necessarily including at least one of each and
every element specifically listed within the list of elements and
not excluding any combinations of elements in the list of elements.
This definition also allows that elements may optionally be present
other than the elements specifically identified within the list of
elements to which the phrase "at least one" refers, whether related
or unrelated to those elements specifically identified. Thus, as a
non-limiting example, "at least one of A and B" (or, equivalently,
"at least one of A 30 or B," or, equivalently "at least one of A
and/or B") can refer, in one embodiment, to at least one,
optionally including more than one, A, with no B present (and
optionally including elements other than B); in another embodiment,
to at least one, optionally including more than one, B, with no A
present (and optionally including elements other than A); in yet
another embodiment, to at least one, optionally including more than
one, A, and at least one, optionally including more than one, B
(and optionally including other elements); etc.
[0153] It should also be understood that, unless clearly indicated
to the contrary, in any methods claimed herein that include more
than one step or act, the order of the steps or acts of the method
is not necessarily limited to the order in which the steps or acts
of the method are recited.
[0154] In the claims, as well as in the specification above, all
transitional phrases such as "comprising," "including," "carrying,"
"having," "containing," "involving," "holding," "composed of," and
the like are to be understood to be open-ended, i.e., to mean
including but not limited to. Only the transitional phrases
"consisting of" and "consisting essentially of" shall be closed or
semi-closed transitional phrases, respectively, as set forth in the
United States Patent Office Manual of Patent Examining Procedures,
Section 2111.03.
* * * * *