Composite electrodes for lithium ion battery and method of making

Abstract

A method for making a composite electrode for a lithium ion battery comprises the steps of: preparing a slurry containing particles of inorganic electrode material(s) suspended in a solvent; preheating a porous metallic substrate; loading the metallic substrate with the slurry; baking the loaded substrate at a first temperature; curing the baked substrate at a second temperature sufficient to form a desired nanocrystalline material within the pores of the substrate; calendaring the cured composite to reduce internal porosity; and, annealing the calendared composite at a third temperature to produce a self-supporting multiphase electrode. Because of the calendaring step, the resulting electrode is self-supporting, has improved current collecting properties, and improved cycling lifetime. Anodes and cathodes made by the process, and batteries using them, are also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application is related to U.S. patent application Ser. No. ______ entitled, “Composite Electrodes for Lithium Ion Battery and Method of Making” filed on even date herewith by the present inventors, the entire disclosure of which is incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The invention pertains to methods of making composite electrodes for lithium ion batteries, and more particularly, to methods of fabricating composite cathodes suitable for both liquid cell and all-solid-state cell applications, and batteries containing the same.[0004]2. Description of Related Art[0005]Electrodes, especially the cathodes, for traditional lithium ion batteries are typically multi-component structures. They include: nanoparticles of the active cathode material for lithium storage; an electron conductor that is either carbon black, carbon nanotube, carbon fiber, or graphene; a binding agent that is...

AI Technical Summary

Benefits of technology

The invention relates to a method for making a composite electrode for a lithium ion battery by preparing a slurry containing particles of a selected inorganic electrode material suspended in a selected solvent, preheating a porous metallic substrate, loading the preheated metallic substrate with the slurry, baking the loaded substrate at a first selected temperature, curing the baked substrate at a second selected temperature sufficient to form a desired nanocrystalline material within the pores of the substrate, calendaring the cured composite to reduce internal porosity, and annealing the calendared composite at a third temperature greater than the second temperature to produce a self-supporting multiphase electrode. The invention also relates to a cathode for a lithium ion battery comprising a first phase comprising an inorganic energy storage material, a second phase comprising a solid state lithium ion conductor, and a third phase comprising a reticulated metal structure, interspersed throughout the first and second phases, the metal structure forming a structural reinforcement and a current collector, and an anode for a lithium ion battery comprising a first phase comprising a lithium storage material, a second phase comprising a solid state lithium ion conductor, and a third phase comprising a reticulated metal structure. The invention also relates to a lithium ion battery comprising a cathode and an anode separated by a lithium-conducting electrolyte.

Problems solved by technology

Carbon-coating of the powder particles is necessary to achieve good performances because of the rather poor electronic conductivity of NASICON structures.

Thus the transport of lithium ion from the liquid and the energy storage particles is limited by the surrounding insulative binder film; this leads to local solid electrolyte interface (SEI) layer formation around the particles because of the side reaction taking place between the liquid electrolyte and organic binder film.

The continuous adverse change in the properties of this SEI layers limit the performance and the lifetime of the traditional lithium ion cells.

The energy density of the cell is low because of thick electrodes, also the fundamental low cycle life affecting the traditional cell due to SEI layer has not been addressed by this approach.

Importantly, the LiCoO2 particle coating was done with Pulse Laser Deposition (PLD), a process that is relatively unsuitable for routine manufacturing.

And all the solid state cells were made by pressing the stack of powder of various components into small area cylindrical disk, a cell fabrication technique that is not readily scalable.

The mechanical contact between the particles that dependent on pressing pressure provides less than ideal electrical contact between various particles.

The latter combined with too thick solid state electrolyte layer in the cell leads to undesirable overall cell impedance that limits the extractable capacity.

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