Battery pack assembly and method thereof

Abstract

The invention discloses a battery pack assembly and a method thereof. A battery cell is described having an anode and a cathode with a catalytic separator therebetween and sealed within a cell housing. The catalytic separator is a substrate having a catalytic coating disposed thereon. The catalytic coating includes a bimetallic catalyst disposed on a support material. The bimetallic catalyst comprises rhodium or ruthenium and a second transition metal. The lithium in the zeolite is used as a co-catalyst to accelerate the hydroformylation reaction.

Description

Technical Field

[0001] A battery cell, a catalytic separator for a battery cell, and a method for forming a separator for a battery cell. Background Art

[0002] The concepts described herein relate to arrangements of battery cells and battery assemblies.

[0003] Lithium-ion battery cells are susceptible to chemical and mechanical degradation, resulting in the generation of large amounts of gases due to undesirable side reactions. These gases primarily contain hydrogen, methane, ethylene, carbon monoxide, and other hydrocarbons, all of which are flammable. The accumulation of these gases can cause battery swelling, adversely affecting the diffusion of lithium ions in the electrolyte. In addition, it raises concerns such as the risk of potential battery cell rupture, liquid electrolyte leakage, and thermal events, all of which can reduce the service life of the battery cells. Summary of the invention

[0004] In one embodiment, the concepts herein provide a battery cell having an anode and a cathode with a catalytic separator therebetween and sealed within a cell housing.

[0005] In one embodiment, the concepts herein provide a battery cell having a plurality of anodes and cathodes and one or more catalytic separators, all sealed within a cell housing.

[0006] The catalytic separator is a planar substrate having a catalytic coating disposed thereon. The catalytic coating comprises a bimetallic catalyst disposed on a support material. The bimetallic catalyst comprises rhodium or ruthenium and a second transition metal.

[0007] The catalytic separator is used to convert combustible gases that may be formed within the battery cell into liquids by a hydroformylation process in the electrochemical environment of the battery cell. This can operate to inhibit the accumulation of gases within the battery cell. A transition metal, such as rhodium or ruthenium, forms a bimetallic catalyst with a second transition metal ion dissolved from the cathode into the electrolyte, and the lithium in the zeolite acts as a co-catalyst to accelerate the hydroformylation reaction. The aldehyde formed can be preferentially trapped in the zeolite pores of the catalytic separator and thus avoid damage to the liquid electrolyte.

[0008] One aspect of the present disclosure may include a battery cell including a catalytic separator between an anode and a cathode. The catalytic separator has a catalytic coating disposed on a planar substrate. The catalytic coating includes a bimetallic catalyst disposed on a support material.

[0009] Another aspect of the present disclosure may include a coating disposed on a substrate having a thickness between 300 nanometers and 10 micrometers.

[0010] Another aspect of the present disclosure may include a rhodium catalyst.

[0011] Another aspect of the present disclosure may include a ruthenium catalyst.

[0012] Another aspect of the present disclosure may include the catalyst being one of nickel, cobalt, manganese, zinc, copper, or iron.

[0013] Another aspect of the present disclosure may include the catalyst being one of platinum or palladium.

[0014] Another aspect of the present disclosure may include the support material being one of a lithium-zeolite, a zeolite, a metal-organic framework, alumina (Al2O3), silica (SiO2), titania, boehmite, or magnesium oxide (MgO).

[0015] Another aspect of the present disclosure may include a catalytic coating disposed on only one side of a planar substrate.

[0016] Another aspect of the present disclosure may include a catalytic coating disposed on both sides of a planar substrate.

[0017] Another aspect of the present disclosure may include a battery cell having a plurality of anodes and a plurality of cathodes arranged in a stack and a plurality of catalytic separators, the catalytic separators including a first catalytic separator and a second catalytic separator. The first catalytic separator is disposed on a first end of the stack and the second catalytic separator is disposed on a second end of the stack.

[0018] Another aspect of the present disclosure may include a catalytic separator for a battery cell having a catalytic coating disposed on a substrate, wherein the catalytic coating comprises a catalyst disposed on a support material.

[0019] Another aspect of the present disclosure may include a catalyst of rhodium, ruthenium, nickel, cobalt, manganese, zinc, copper, iron, platinum, palladium, or combinations thereof.

[0020] Another aspect of the present disclosure may include a substrate for the catalytic separator that is made of one of an aramid material, a polyethylene material, or a polypropylene material.

[0021] Another aspect of the present disclosure may include a method of forming a separator for a battery cell, the method comprising: preparing a solvent comprising a lithiated zeolite and a catalytic material comprising a salt; performing solid state ion exchange on the solvent; and applying the solvent to a surface of a substrate.

[0022] Another aspect of the present disclosure may include reducing the particle size of the solvent prior to applying the solvent.

[0023] The above features and advantages and other features and advantages of the present teachings are apparent from the following detailed description of some modes for carrying out the present teachings as defined in the appended claims when taken in conjunction with the accompanying drawings.

[0024] The present invention discloses the following embodiments:

[0025] 1. A battery cell, comprising:

[0026] a catalytic separator between the anode and cathode;

[0027] The catalytic separator comprises a catalytic coating disposed on a planar substrate; and

[0028] The catalytic coating is a bimetallic catalyst disposed on a support material comprising lithium.

[0029] 2. The battery cell of embodiment 1, wherein the bimetallic catalyst comprises rhodium and a second transition metal.

[0030] 3. The battery cell of Embodiment 2, wherein the second transition metal comprises one of nickel, cobalt, manganese, zinc, copper, or iron.

[0031] 4. The battery cell of embodiment 2, wherein the bimetallic catalyst is bonded to the substrate by ion exchange.

[0032] 5. The battery cell of Embodiment 1, wherein the bimetallic catalyst comprises ruthenium and a second transition metal, and wherein the second transition metal comprises one of nickel, cobalt, manganese, zinc, copper, or iron.

[0033] 6. The battery cell of embodiment 1, wherein the coating disposed on the substrate has a thickness of 300 nanometers to 10 micrometers.

[0034] 7. The battery cell of Embodiment 1, wherein the support material comprises one of a zeolite, a metal-organic framework (MOF), alumina (Al2O3), silica (SiO2), titania, boehmite, or magnesium oxide (MgO).

[0035] 8. The battery cell according to embodiment 1, wherein the catalytic coating is disposed on only one side of the substrate.

[0036] 9. The battery cell according to embodiment 1, wherein the catalytic coating is disposed on both sides of the substrate.

[0037] 10. The battery cell according to embodiment 1,

[0038] wherein the battery cell comprises a plurality of anodes and a plurality of cathodes arranged in a stack; and

[0039] a plurality of catalytic separators, including a first catalytic separator and a second catalytic separator;

[0040] Wherein a first catalytic separator is disposed at a first end of the stack, and wherein a second catalytic separator is disposed at a second end of the stack.

[0041] 11. A catalytic separator for a battery cell, comprising:

[0042] a catalytic coating disposed on a substrate; and

[0043] The catalytic coating includes a bimetallic catalyst disposed on a support material comprising lithium.

[0044] 12. The catalytic separator of embodiment 11, wherein the coating disposed on the substrate has a thickness of 300 nanometers to 10 micrometers.

[0045] 13. A catalytic isolation element according to embodiment 11, wherein the carrier material includes one of lithium-zeolite, zeolite, metal-organic framework, aluminum oxide (Al2O3), silicon dioxide (SiO2), titanium dioxide, boehmite or magnesium oxide (MgO).

[0046] 14. The catalytic separator according to embodiment 11, wherein the substrate of the catalytic separator is made of one of aromatic polyamide material, polyethylene material or polypropylene material.

[0047] 15. The catalytic separator of embodiment 11, wherein the bimetallic catalyst comprises rhodium and a second transition metal.

[0048] 16. The catalytic separator of embodiment 15, wherein the second transition metal comprises one of nickel, cobalt, manganese, zinc, copper or iron.

[0049] 17. The catalytic separator of embodiment 15, wherein the bimetallic catalyst is bonded to the substrate by ion exchange.

[0050] 18. A catalytic separator according to embodiment 11, wherein the bimetallic catalyst comprises ruthenium and a second transition metal, and wherein the second transition metal comprises one of nickel, cobalt, manganese, zinc, copper or iron.

[0051] 19. A method for forming a separator for a battery cell, the method comprising:

[0052] preparing a solvent having a suspended material comprising a lithiated zeolite and a catalytic material comprising a salt;

[0053] Solid state ion exchange of solvents; and

[0054] The solvent is applied as a slurry coating onto the surface of the substrate to form the spacer.

[0055] 20. The method of embodiment 19, further comprising reducing the particle size of the suspended material prior to applying the solvent. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] One or more embodiments will now be described by way of example with reference to the accompanying drawings, in which:

[0057] Figure 1 Schematically illustrated is an exploded isometric view of a battery cell according to the present disclosure including an anode, a cathode, and a catalytic separator arranged in a stack.

[0058] Figure 2 A partial cross-sectional side view of an embodiment of a battery cell including a catalytic separator according to the present disclosure is schematically shown.

[0059] Figure 3 A method of forming a catalytic separator according to the present invention is illustrated.

[0060] Figure 4 A partial cross-sectional side view of another embodiment of a battery cell including a catalytic separator according to the present disclosure is schematically shown.

[0061] Figure 5 A partial cross-sectional side view of another embodiment of a battery cell including a catalytic separator according to the present disclosure is schematically shown.

[0062] The drawings are not necessarily drawn to scale and present somewhat simplified representations of various features of the present disclosure as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes. The details associated with these features may be determined in part by the specific intended application and use environment. DETAILED DESCRIPTION

[0063] As described and shown herein, the components of the disclosed embodiments can be arranged and designed in various different configurations. Therefore, the following detailed description is not intended to limit the scope of the present disclosure as claimed, but is only a representative of its possible embodiments. In addition, although many specific details are set forth in the following description to provide a thorough understanding of the embodiments disclosed herein, some embodiments can be practiced without some of these details. In addition, for the purpose of clarity, some technical materials understood in the related art are not described in detail to avoid unnecessarily blurring the present disclosure. In addition, the accompanying drawings are in simplified form and do not have an accurate scale. For the purpose of convenience and clarity, directional terms such as top, bottom, left, right, above, above, below, below, behind and in front can be used to help describe the accompanying drawings. These and similar directional terms are illustrative and should not be interpreted as limiting the scope of the present disclosure. In addition, the present disclosure as illustrated and described herein can be practiced without the presence of elements not specifically disclosed herein.

[0064] Referring to the drawings, wherein like reference numerals correspond to the same or similar parts throughout the several views, Figure 1 An embodiment of a prismatic lithium-ion battery cell 10 is schematically shown and includes an anode 20 , a catalytic separator 100 , and a cathode 30 arranged in a stack and sealed in a flexible bag 60 containing an electrolytic material 62 .

[0065] The anode 20, the catalytic separator 100, and the cathode 30 are configured in a planar shape having the same or similar surface areas.

[0066] The first negative electrode battery cell tab 26 and the second positive electrode battery cell tab 36 protrude from the flexible bag 60. The terms "anode" and "negative electrode" are used interchangeably. The terms "cathode" and "positive electrode" are used interchangeably. A single arrangement of anode 20, catalytic separator 100, and cathode 30 is shown. It should be understood that a variety of arrangements of anode 20, catalytic separator 100, and cathode 30 may be arranged and electrically connected in the flexible bag 60 depending on the specific application of the battery cell 10.

[0067] Alternatively, the lithium-ion battery cell 10 includes an anode 20, a catalytic separator 100, a cathode 30, and an electrolytic material 62 arranged in a stack and sealed in a rigid-walled cell casing.

[0068] Alternatively, the lithium-ion battery cell 10 includes an anode 20, a catalytic separator 100, a cathode 30, and an electrolytic material 62 arranged in a stack and sealably formed in a cylindrical cell casing.

[0069] Anode 20 includes a first active material 22 disposed on an anode current collector 24. Anode current collector 24 is a metal substrate having a foil portion 25 extending from the first active material 22 to form a first battery cell tab 26. In one embodiment, anode current collector 24 is made of copper, a copper alloy, stainless steel, nickel, etc., or another material that does not alloy with lithium.

[0070] Cathode 30 includes a second active material 32 disposed on a cathode current collector 34. Cathode current collector 34 is a metal substrate having a foil portion 35 extending from the second active material 32 to form a second battery cell tab 36. In one embodiment, cathode current collector 34 is made of aluminum or an aluminum alloy.

[0071] Anode and cathode current collectors 24, 34 are thin metal plate-shaped elements that contact their respective first and second active materials over a substantial interfacial surface area. The purpose of anode and cathode current collectors 24, 34 is to exchange free electrons with their respective first and second active materials during electrochemical discharge and charge events.

[0072] The catalytic separator 100 is disposed between the positive electrode 30 and the negative electrode 20 to physically separate and electrically insulate the positive electrode 30 and the negative electrode 20. For additional details regarding the catalytic separator, refer to Figure 2 and described below.

[0073] The electrolyte material 62 that conducts lithium ions is housed within the catalytic separator 100 and is exposed to each of the positive electrode 30 and the negative electrode 20 to allow lithium ions to move between the positive electrode 30 and the negative electrode 20. The lithium ions extracted from the negative electrode 20 during discharge or the lithium ions extracted from the positive electrode 30 during charge release electrons, which flow through the current collectors 24 and 34, respectively, through an external circuit connected to a load or a charger, and then flow to the opposing current collectors (34 and 24) and electrodes (30 and 20), where they reduce lithium ions when intercalated.

[0074] The negative electrode 20 and the positive electrode 30 are manufactured as electrode materials capable of intercalating and deintercalating lithium ions. The electrode materials of the positive electrode 30 and the negative electrode 20 are formulated to store intercalated lithium at different electrochemical potentials relative to a common reference electrode (e.g., lithium). In the structure of the electrode pair 20, the negative electrode 20 stores intercalated lithium at a lower electrochemical potential (i.e., a higher energy state) than the positive electrode 30, so that when the negative electrode 20 is lithiated, there is an electrochemical potential difference between the positive electrode 30 and the negative electrode 20. The electrochemical potential difference of each battery cell 10 results in a charging voltage in the range of 3V to 5V and a nominal open circuit voltage in the range of 2.9V to 4.2V. These properties of the negative electrode 30 and the positive electrode 20 allow lithium ions to be reversibly transferred between the positive electrode 30 and the negative electrode 20 spontaneously (discharge phase) or by applying an external voltage (charge phase) during the operation cycle of the electrode pair 20. The thickness of each of the positive electrode 30 and the negative electrode 20 is between 30 micrometers (μm) and 150 μm.

[0075] The negative electrode 20 has an anode material in the form of a lithium main material, such as graphite, silicon or lithium titanate. The lithium main material can be mixed with a polymer binder material to provide a negative electrode 20 with structural integrity, and in one embodiment, a conductive fine particle diluent is provided. The lithium main material is preferably graphite, and the polymer binder material is preferably one or more of polyvinylidene fluoride (PVdF), ethylene propylene diene monomer rubber (EPDM), styrene butadiene rubber (SBR), carboxymethyl cellulose (CMC), polyacrylic acid or a mixture thereof. Graphite is generally used to make the negative electrode 20 because, in addition to being relatively inert, its layered structure also exhibits favorable lithium insertion and extraction characteristics, which helps to provide the desired energy density for the battery electrode pair 20. Various forms of graphite that can be used to construct the negative electrode 20 are commercially available. The conductive diluent can be, for example, fine particles of high surface area carbon black.

[0076] The positive electrode 30 has a cathode material in the form of a lithium-based active material that stores intercalated lithium at a higher electrochemical potential (relative to a common reference electrode) than the anode material used to make the lithium host material of the negative electrode 20. For the same purpose, the same polymer binder materials (PVdF, EPDM, SBR, CMC, polyacrylic acid) and conductive fine particle diluent (high surface area carbon black) that can be used to construct the negative electrode 20 can also be mixed with the lithium-based active material of the positive electrode 30. The lithium-based active material is preferably a layered lithium transition metal oxide, such as lithium cobalt oxide, a spinel lithium transition metal oxide, such as spinel lithium manganese oxide, a lithium polyanion, such as nickel-manganese-cobalt oxide, lithium iron phosphate or lithium fluorophosphate. Some other suitable lithium-based active materials that can be used as lithium-based active materials include lithium nickel oxide, lithium aluminum manganese oxide, and lithium vanadium oxide to list examples of alternatives. Mixtures including one or more of these listed lithium-based active materials can also be used to make the positive electrode 30.

[0077] Reference now Figure 2 , continued reference Figure 1 , shows a portion of a lithium-ion battery cell 10 and includes an anode 20, a catalytic separator 100 including a catalytic coating 120, and a cathode 30, which are arranged in a stack. In this embodiment, the catalytic separator 100 has a catalytic coating 120 arranged on both surfaces of a substrate 110.

[0078] Cathode 30 includes cathode material 32 disposed on first current collector 34, wherein cathode material 32 abuts first surface 111 of catalytic separator 100. Anode 20 includes anode material 22 disposed on second current collector 24, wherein anode material 22 abuts second surface 112 of catalytic separator 100.

[0079] The catalytic separator 100 includes a substrate 110, which is arranged as a planar sheet having a first surface 111 and a second surface 112, wherein a catalytic coating 120 is bonded to either or both of the first surface 111 and the second surface 112 by spraying, dipping or other methods. In one embodiment, and as shown, the catalytic coating 120 is bonded to both the first surface 111 and the second surface 112. Alternatively, the catalytic coating 120 is bonded to only the first surface 111, while the second surface 112 is uncoated. Alternatively, the catalytic coating 120 is bonded to only the second surface 112, while the first surface 111 is uncoated. The catalytic coating 120 includes a bimetallic catalyst 122 disposed on a support material 124.

[0080] The substrate 110 is formed with a planar sheet and has one or more porous polymer layers (or base films), which can be composed of any of a variety of polymers individually. For simplicity, one such polymer layer is shown here. Each of the one or more polymer layers can be a polyolefin. Some specific examples of polyolefins are polyethylene (PE) (and variants, such as HDPE, LDPE, LLDPE and UHMWPE), polypropylene (PP), or blends of PE and PP, aromatic polyamides, polyimides or polyamides. The role of the one or more polymer layers is to electrically insulate and physically isolate the anode 20 from the cathode 30.

[0081] The catalytic coating 120 includes a bimetallic catalyst 122 disposed on a support material 124. The catalytic coating 120 is deposited and attached to the substrate 110 at a thickness between 300 nanometers and 10 microns.

[0082] The bimetallic catalyst 122 may be arranged as a bimetallic catalyst comprising rhodium (Rh), ruthenium (Ru), zinc (Zn) or another catalytic material and a second transition metal. The second transition metal may be one or more of nickel, cobalt, manganese, zinc, copper, iron, platinum or palladium. Some of them, such as nickel, cobalt or manganese, may be dissolved from the cathode.

[0083] The support material 124 may be composed of one or more of lithium-zeolite, zeolite, metal-organic framework, aluminum oxide (Al2O3), silicon dioxide (SiO2), titanium dioxide, boehmite, or magnesium oxide (MgO).

[0084] The catalytic separator 100 with the catalytic coating 120 is advantageously arranged as a heterogeneous bimetallic catalyst capable of performing a hydroformylation reaction. The hydroformylation reaction includes lithium in a zeolite, which acts as a promoter to accelerate the hydroformylation reaction. The hydroformylation reaction, also known as the oxo process, includes the addition of hydrogen atoms and formyl groups to molecules of a compound containing a double bond by reacting with hydrogen and carbon monoxide to form one or more aldehydes. The energy barrier to the catalytic reaction can be overcome by an electrochemical potential applied between the anode and the cathode.

[0085] In the case of the hydroformylation reaction in the embodiments of the battery cell 10 described herein, the aldehyde formed in situ can be adsorbed by the zeolite coating, thereby inhibiting the accumulation of gas within the cell. The entrapped transition metal will combine with ruthenium or rhodium to form a heterogeneous bimetallic catalyst, while the lithium is first in the zeolite and secondly as a co-catalyst to accelerate the hydroformylation reaction. The aldehyde formed will be preferentially entrapped in the zeolite pores.

[0086] A non-limiting example of a hydroformylation reaction can be represented as follows:

[0087]

[0088] Bimetallic catalysts of Rh (trace) + second transition metal such as Co, Ni, Mn enable the use of heterogeneous bimetallic catalysts for hydroformylation reactions that entrap transition metal ions in a Li-zeolite separator.

[0089] Reference again Figure 1 , continued reference Figure 2 In one embodiment, the battery cell 10 is a planar lithium-ion battery cell 10 sealed in a flexible bag containing an electrolytic material 62, and as shown. Alternatively, the battery cell 10 is a planar lithium-ion battery cell 10 contained in a sealed rigid housing 60 (e.g., a sealed rectangular prism including the electrolytic material 62). In one embodiment, the electrolytic material 62 is a solid material. The battery cell 10 may have a rectangular shape, or a non-rectangular shape, or other configurations. In one embodiment, a reference electrode (not shown) may be disposed between the anode 20 and the cathode 30.

[0090] For each battery cell 10, a single electrode pair is shown including an arrangement of an anode 20, a solid catalytic separator 100, and a cathode 30. It will be appreciated that multiple electrode pairs may be arranged and electrically connected within the sealed cell housing 60 depending on the specific application of the battery cell 10.

[0091] Anode 20 includes a first active material disposed on an anode current collector 24. Anode current collector 24 is a metal substrate having a foil portion extending from the first active material to form an anode tab 22.

[0092] Cathode 30 includes a second active material disposed on a cathode current collector 34 , wherein cathode current collector 34 has a foil portion extending from the second active material to form a cathode tab 32 .

[0093] Anode and cathode current collectors 24, 34 are thin metal plate-shaped elements that contact their respective first and second active materials over a substantial interfacial surface area. The purpose of anode and cathode current collectors 24, 34 is to exchange free electrons with their respective first and second active materials during discharge and charge.

[0094] In one embodiment, the anode current collector 24 is a flat plate-shaped metal substrate in the form of a rectangular planar sheet. The anode current collector 24 is made of one of copper, copper alloy, stainless steel, nickel, etc. or another material that is not alloyed with lithium. In one embodiment, the anode current collector 24 has a thickness of 0.02 mm or close to 0.02 mm. The first active material may be an indium nitride layer applied to one or both surfaces of the anode current collector 24.

[0095] The cathode current collector 34 is a metal substrate in the form of a planar sheet made of aluminum or an aluminum alloy and has a thickness of 0.02 mm or close to 0.02 mm in one embodiment. The solid catalytic separator 100 is disposed between the anode 20 and the cathode 30 to physically separate and electrically insulate the anode 20 and the cathode 30.

[0096] The lithium ion conducting electrolyte material 62 is an element of the solid catalytic separator 100 and is exposed to each of the anode 20 and the cathode 30 to allow lithium ions to move between the anode 20 and the cathode 30. Lithium ions are stripped from the anode 20 during discharge, or from the cathode 30 during charge to release electrons, which flow through the current collectors 24, 34, respectively, through an external circuit connected to a load or a charger, and then flow to the opposite current collectors (34, 24) and electrodes (30 and 20), where they reduce lithium ions when they are intercalated or plated.

[0097] The anode 20 and the cathode 30 are each manufactured as an electrode material capable of depositing and stripping lithium ions (on the anode) or inserting and deinserting (on the cathode). The electrode materials of the anode 20 and the cathode 30 are formulated to store lithium at different electrochemical potentials relative to a common reference electrode, such as lithium. The anode 20 stores deposited or plated lithium at a lower electrochemical potential (i.e., a higher energy state) than the cathode 30, so that when the anode 20 is lithiated, there is an electrochemical potential difference between the anode 20 and the cathode 30. The electrochemical potential difference of each battery cell 10 results in a charging voltage in the range of 3V to 5V and a nominal open circuit voltage in the range of 2.9V to 4.2V. These properties of the anode 20 and the cathode 30 allow lithium ions to be reversibly transferred between the anode 20 and the cathode 30 spontaneously (discharge phase) or by applying an external voltage (charge phase) during an operating cycle. In one embodiment, the thickness of the anode 20 ranges between 10 micrometers (μm) and 60 μm.

[0098] The solid catalytic separator 100 includes a solid polymer that includes an electrolytic material 62 and can be composed of various polymers that provide thermal stability. The one or more polymer layers function to electrically insulate and physically isolate the anode 20 and the cathode 30. The solid catalytic separator 100 can be further infiltrated with the electrolytic material 62 throughout the pores of the one or more polymer layers. In one embodiment, the electrolytic material 62 includes lithium. The solid separator 100 has a thickness that can be between 10 micrometers (μm) and 60 μm.

[0099] Figure 3A method 300 is illustrated of applying a catalyst to a ceramic coated separator, such as a lithiated zeolite, which first and second converts the combustible gas into a liquid by a hydroformylation process under an electrochemical environment and thus inhibits gas accumulation inside the cell. The trapped second transition metal will combine with the ruthenium or rhodium to form a bimetallic catalyst, while the lithium in the zeolite will act as a co-catalyst to accelerate the hydroformylation reaction. The aldehyde formed will be preferentially trapped in the zeolite pores, thereby avoiding damage to the liquid electrolyte.

[0100] The method 300 begins by forming a lithiated zeolite (step 310). Solid state ion exchange is performed to form a catalyzed lithiated zeolite (step 320). The catalyzed lithiated zeolite is ground or otherwise processed to reduce the particle size to submicron levels, such as 300 nm, and a slurry coating is formed in which the catalyzed lithiated zeolite is in suspension and applied to a substrate surface (step 330).

[0101] The catalyst preparation includes solvent ion exchange between the lithiated zeolite and the catalyst, wherein the catalyst contains salts such as O4PRh, O8P2Rh3, RhCl3, [Rh(NH3)5Cl]Cl2 and Rh(ClO4)3, RuCl3, RuCl3·xH2O, [Ru(NH3)5Cl]Cl2, Ru(NO)(NO3) x (OH) y , and salts such as Zn salts, Mo salts, Co salts, palladium complexes, etc. Solid-state ion exchange is achieved by mixing the lithiated zeolite with a salt-containing catalyst to form a catalyzed lithiated zeolite and reducing the particle size to a submicron size, such as about 300 nm. The catalyzed lithiated zeolite is suspended in a solvent. The separator is coated using a slurry coating method or a dry spray method to bond the catalyzed lithiated zeolite to the substrate surface as a ceramic coating.

[0102] Figure 4 Schematically illustrated is an embodiment of a lithium-ion battery cell 400 that includes an anode 20, a catalytic separator 420 including a reference electrode 415, and a cathode 30, arranged in a stack. In this embodiment, the catalytic separator 400 includes a substrate 410, a reference electrode 415, and a catalytic coating 120, and the reference electrode 415 is interposed between the substrate 410 and the catalytic coating 120. In this embodiment, the catalytic coating 120 is adjacent to the cathode material 32 of the cathode 30.

[0103] Cathode 30 includes cathode material 32 disposed on a first current collector 34. Anode 20 includes anode material 22 disposed on a second current collector 24. Catalytic separator 100 includes substrate 110 arranged as a planar sheet having a first surface 111 and a second surface 112, wherein catalytic coating 120 is bonded to either or both of first surface 111 and second surface 112.

[0104] Figure 5 An embodiment of a lithium-ion battery cell 501 is schematically shown, which includes a stack 505 consisting of a plurality of anodes 20, separators 500, and cathodes 30, wherein catalytic separators 520 are disposed on a first side and a second side of the stack 505. Each catalytic separator 500 includes a substrate 522 and a catalytic coating 524.

[0105] The concept described herein provides a method in which a catalyst, such as a lithiated zeolite, is applied to a ceramic coated separator and the combustible gas formed in the cell housing is converted into a liquid by a hydroformylation process under an electrochemical environment, thereby suppressing the gas accumulation in the cell and improving the battery life. The trapped second transition metal combines with rhodium or ruthenium to form a bimetallic catalyst, and the lithium in the zeolite will act as a co-catalyst to accelerate the hydroformylation reaction. The aldehyde formed will be preferentially trapped in the zeolite pores, and thus damage to the electrolyte can be avoided.

[0106] The lithium in the zeolite acts as a promoter together with the catalyst to synergistically promote the hydroformylation reaction. Reaction byproducts such as aldehydes and alcohols are adsorbed in situ in the zeolite coating. The combustible gas is converted in situ, thus suppressing gas accumulation and battery expansion.

[0107] The detailed description and the accompanying drawings or figures are supportive and descriptive of the present teaching, but the scope of the present teaching is limited only by the claims. Although some embodiments for implementing the present teaching have been described in detail, there are various alternative designs and embodiments for implementing the present teaching defined in the appended claims.

Claims

1. A battery cell, comprising: a catalytic separator between the anode and cathode; The catalytic separator includes a catalytic coating disposed on a planar substrate; as well as The catalytic coating is a bimetallic catalyst disposed on a support material comprising lithium.

2. The battery cell of claim 1, wherein the bimetallic catalyst comprises rhodium and a second transition metal.

3. The battery cell of claim 2, wherein the second transition metal comprises one of nickel, cobalt, manganese, zinc, copper or iron.

4. The battery cell of claim 2, wherein the bimetallic catalyst is bonded to the substrate by ion exchange.

5. The battery cell of claim 1, wherein the bimetallic catalyst comprises ruthenium and a second transition metal, and wherein the second transition metal comprises one of nickel, cobalt, manganese, zinc, copper, or iron.

6. The battery cell of claim 1, wherein the coating disposed on the substrate has a thickness of 300 nanometers to 10 micrometers.

7. The battery cell of claim 1, wherein the catalytic coating is disposed on only one side of the substrate.

8. The battery cell of claim 1, wherein the catalytic coating is disposed on both sides of the substrate.

9. The battery cell according to claim 1, wherein the battery cell comprises a plurality of anodes and a plurality of cathodes arranged in a stack; and a plurality of catalytic separators, including a first catalytic separator and a second catalytic separator; Wherein a first catalytic separator is disposed at a first end of the stack, and wherein a second catalytic separator is disposed at a second end of the stack.

10. A method for forming a separator for a battery cell, the method comprising: preparing a solvent having a suspended material comprising a lithiated zeolite and a catalytic material comprising a salt; Solid-state ion exchange of solvents; as well as The solvent is applied as a slurry coating onto the surface of the substrate to form the spacer.

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