Non-aqueous secondary lithium ion battery cell with metal oxide trapping transition metal

Abstract

A battery cell, a secondary lithium ion battery cell, and a method of forming a secondary lithium ion battery cell for a vehicle. The secondary lithium ion battery unit comprises a positive electrode containing lithium and a transition metal, a negative electrode, a porous diaphragm sandwiched between the positive electrode and the negative electrode, and an electrolyte permeated into the porous diaphragm and in contact with the positive electrode and the negative electrode, and a zeolite particle layer between the porous separator and at least one of the positive electrode and the negative electrode.

Description

Technical Field

[0001] The present invention relates to the field of batteries, and in particular to a non-aqueous secondary lithium ion battery cell having a transition metal trapped in a metal oxide. Background Art

[0002] Electric and hybrid electric vehicle technology has benefited from the development and application of rechargeable secondary batteries that provide energy for the powertrain. Secondary batteries include lithium-ion batteries, which generally include a positive electrode, a negative electrode, a separator, and an electrolyte. The positive electrode provides a source of lithium ions, which determines the capacity and average voltage of the battery. The negative electrode stores and releases lithium ions received from the positive electrode. The separator prevents the positive and negative electrodes from contacting. The electrolyte is the medium between the positive and negative electrodes, in which the lithium ions move.

[0003] Lithium cathodes containing transition metals, particularly manganese, have been introduced, such as lithium manganese oxide (LMO), lithium manganese (LNMO), lithium-rich manganese (LMR), and lithium iron manganese phosphate (LFMP) cathodes. However, transition metals such as manganese are subject to transition metal dissolution during lithium ion insertion and deintercalation due to the Jahn-Teller effect, which refers to the distortion of nonlinear molecular systems during lithium ion insertion and deintercalation, thereby reducing their symmetry and energy. One solution to the transition metal dissolution problem is to trap the dissolved transition metals in the battery electrolyte. Efforts have been made to incorporate zeolites into battery structures to capture transition metals using adhesive materials or by coating zeolite powders onto various components of the battery cell. However, the hydrophilic nature of zeolites complicates these efforts. Due to their relatively large surface area, zeolites can easily absorb large amounts of water, thereby increasing the conductivity of the zeolite while also introducing water into the battery system.

[0004] Therefore, while existing secondary lithium-ion battery cells achieve their intended purposes, a need remains for new and improved secondary lithium-ion battery cells. Summary of the invention

[0005] According to several aspects, the present disclosure relates to a method for forming a battery cell. The method includes dispersing a plurality of zeolite particles in a non-aqueous solvent to form a zeolite dispersion. The method also includes providing a positive electrode and a negative electrode, wherein the positive electrode includes a positive electrode and a positive current collector, and the negative electrode includes a negative electrode and a negative current collector. The method also includes at least partially disposing a porous diaphragm between the positive electrode and the negative electrode. In addition, the method includes dispersing the zeolite dispersion between the porous diaphragm and at least one of the positive electrode and the negative electrode to form a zeolite particle layer, and sandwiching the porous diaphragm and the zeolite particle layer between the positive electrode and the negative electrode.

[0006] According to the above embodiment, the zeolite particles are present in the solvent at 0.1% by mass to 30% by mass based on the total mass of the zeolite dispersion.

[0007] In any of the above embodiments, the zeolite dispersion contains a surfactant, and the content of the surfactant is 0.1 mass % to 2 mass % of the total mass of the zeolite dispersion.

[0008] In any of the above embodiments, the zeolite dispersion does not include a polymeric binder.

[0009] In any of the above embodiments, the non-aqueous solvent exhibits a boiling point below 120°C.

[0010] In any of the above embodiments, the method further comprises evaporating the non-aqueous solvent from the zeolite dispersion.

[0011] In any of the above embodiments, the battery cell is used in a battery, the battery includes an electrolyte and the non-aqueous solvent is the electrolyte.

[0012] In any of the above embodiments, disposing the porous membrane at least partially between the positive electrode and the negative electrode includes staggering the positive electrodes in the first folds of the porous membrane and staggering the negative electrodes in the second folds of the porous membrane. In other embodiments, dispersing the zeolite dispersion includes spraying the zeolite dispersion on a first side of the porous membrane in contact with the positive electrode. In alternative or additional embodiments, dispersing the zeolite dispersion includes spraying the zeolite dispersion on a second side of the porous membrane in contact with the negative electrode.

[0013] Alternatives to at least partially positioning a porous membrane between the positive electrode and the negative electrode include interlacing the positive electrodes within a first fold of the porous membrane and interlacing the negative electrodes within a second fold of the porous membrane in any of the above embodiments, positioning the porous membrane at least partially between the positive electrode and the negative electrode includes winding a first membrane strip, a positive electrode strip, a second membrane strip, and a negative electrode strip around a mandrel. In other embodiments, positioning the porous membrane at least partially between the positive electrode and the negative electrode includes winding the first membrane, the positive electrode, the second membrane, and the negative electrode around a mandrel. In other embodiments, dispersing the zeolite dispersion includes spraying the zeolite dispersion between the first membrane and the positive electrode, wherein the first membrane is located between the positive electrode and the negative electrode. In other or alternative embodiments, dispersing the zeolite dispersion includes spraying the zeolite dispersion between the first membrane and the negative electrode.

[0014] In any of the above embodiments, the method includes placing a battery cell in a pouch, adding electrolyte to the pouch, and sealing the pouch.

[0015] According to another aspect, the present disclosure relates to a secondary lithium-ion battery cell for a vehicle. The battery cell includes a positive electrode comprising lithium and a transition metal, a negative electrode, a porous separator sandwiched between the positive electrode and the negative electrode, an electrolyte that penetrates into the porous separator and contacts the positive electrode and the negative electrode, and a zeolite particle layer located between the porous separator and at least one of the positive electrode and the negative electrode. In an embodiment, the zeolite particle layer does not include a binder for the zeolite particle layer in the battery cell.

[0016] In the above embodiments, the layer of zeolite particles is between 0.5 microns and 2 microns and exhibits a porosity between 10% and 90% of the total volume defined by the layer of zeolite particles.

[0017] In any of the above embodiments, the layer of zeolite particles comprises zeolite particles exhibiting one or more specific surface areas exceeding 100 m2 / g as measured using the BET (Brunauer, Emmett and Teller) theoretical technique.

[0018] In any of the above embodiments, the zeolite has the formula M n+ 1 / n (AlO2)-(SiO2) x *yH2O, where M n+ 1 / n is one of a metal ion and a hydrogen ion, x is between 1 and 30, n is the charge of the metal particle, which is between 1 and 3, and y is between 1 and 100.

[0019] According to another aspect, the present disclosure relates to a secondary lithium-ion battery for a vehicle. The battery includes a housing and one or more battery cells sealed in a bag and stacked in the housing. The battery cell includes: a positive electrode comprising a positive electrode formed of lithium and a transition metal; a negative electrode; a porous diaphragm sandwiched between the positive electrode and the negative electrode; an electrolyte that penetrates into the porous diaphragm and contacts the positive electrode and the negative electrode; and a zeolite particle layer located between the porous diaphragm and at least one of the positive electrode and the negative electrode. The zeolite particle layer does not include an adhesive for bonding the zeolite particle layer in the battery cell. The battery also includes a negative electrode tab connected to a portion of the negative electrode extending out of the bag and a positive electrode tab connected to a portion of the positive electrode extending out of the bag. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0021] Figure 1 A vehicle including a propulsion system utilizing a battery is shown according to various embodiments described herein.

[0022] Figure 2AA battery including a non-aqueous secondary lithium ion battery cell including a transition metal trapped in a metal oxide according to various embodiments described herein is shown.

[0023] Figure 2B A battery cell containing a transition metal trapped in a metal oxide according to various embodiments described herein is shown.

[0024] Figure 3A Arrangements of lithium-ion battery cells containing transition metals trapped in metal oxides according to various embodiments described herein are shown.

[0025] Figure 3B Arrangements of lithium-ion battery cells containing transition metals trapped in metal oxides according to various embodiments described herein are shown.

[0026] Figure 3C Arrangements of lithium-ion battery cells containing transition metals trapped in metal oxides according to various embodiments described herein are shown.

[0027] Figure 4 Methods of forming a lithium-ion battery cell containing a transition metal trapped in a metal oxide according to various embodiments described herein are shown.

[0028] Figure 5 A system for fabricating a lithium-ion battery cell containing a transition metal trapped in a metal oxide according to various embodiments described herein is shown.

[0029] Figure 6 A system for fabricating a lithium-ion battery cell containing a transition metal trapped in a metal oxide according to various embodiments described herein is shown.

[0030] Fig. 7A A system for manufacturing a lithium-ion battery cell according to various embodiments described herein is shown.

[0031] Figure 7B A system for manufacturing a lithium-ion battery cell according to various embodiments described herein is shown. DETAILED DESCRIPTION

[0032] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application or use. Furthermore, there is no intention to be bound by any express or implied theory presented in the preceding introduction, overview or the following detailed description. It should be understood that throughout the drawings, corresponding reference numerals indicate similar or corresponding parts and features.

[0033] Reference will now be made in detail to several examples of the present disclosure illustrated in the accompanying drawings. Whenever possible, the same or similar reference numerals are used in the drawings and description to refer to the same or similar components or steps. The drawings are in simplified form and not drawn to exact scale.

[0034] The present disclosure relates to non-aqueous secondary lithium-ion battery cells having transition metals captured in metal oxides, batteries containing such battery cells, vehicles containing such batteries, and systems and methods for making batteries containing transition metal positive electrodes and a zeolite particle layer for capturing transition metal ions released from the positive electrode.

[0035] As used herein, the term "vehicle" is not limited to automobiles. Although the technology is primarily described herein in conjunction with electric vehicles, the technology is not limited to electric vehicles and may also be hybrid electric vehicles. In addition, these concepts may be widely applicable to a variety of fields, such as components used in motorcycles, mopeds, locomotives, aircraft, ships and other vehicles, and other applications using batteries, such as portable power stations, such as portable power stations used to power remote work locations and emergency backup power, and permanent power stations associated with buildings and equipment, all of which can be powered by, for example, solar or wind turbine generator systems, power supplies, fuel generators such as gasoline or diesel generators, and Stirling engines.

[0036] Figure 1 The vehicle 100 is shown including a propulsion system 120. The propulsion system 120 generally includes an electric motor 124 and a secondary battery 126 for powering the electric motor 124. Additionally, in many embodiments of the propulsion system 120, the propulsion system 120 includes an inverter 128 for changing power from DC (direct current) provided by the battery 126 to AC (alternating current) used by the electric motor 124. The inverter 128 may be included in a power electronics module 130 that includes, for example, transistors and diodes for switching power from DC to AC and vice versa.

[0037] The controller 132 is connected to the inverter 128 and is programmed to control and manage the operation of the motor 124 and related hardware including the inverter 128. The motor 124 is connected to the transmission (drive unit) 136 and the drive train 138, which transmits mechanical power and rotation to the wheels 140 of the vehicle 100. The controller 132 includes one or more processors and tangible non-transitory memory 134.

[0038] Referring again to the motor 124, the motor 124, which is powered by the battery 126, includes a stator 142 and a rotor 144 disposed together with the stator 142. The stator 142 is the fixed portion of the motor 124. The stator 142 provides a rotating magnetic field, with which the fixed magnetic field of the rotor 144 attempts to align, causing the rotor 144 to rotate in a so-called "motor" mode. In other applications, the rotating field of the rotor 144 (caused by the physical rotation) generates an electric current in the stator 142 - this mode of operation is called "generation" and the motor 124 used in this manner is called a generator. In traction motor vehicle applications, the driving mode provides motion to the vehicle 100. When the vehicle is in the process of stopping, the generating mode captures some of the energy recovered from braking and stores it back into the vehicle battery 126.

[0039] refer to Figure 2A and Figure 2B as well as FIG. 3A to FIG. 3C , showing a method for providing a power source for an electric vehicle 100 (e.g., Figure 1 An example of a secondary battery 126 for supplying power to an electric vehicle 100 is shown. Figure 2A , the battery 126 is shown connected to a load 148 (e.g., the motor 124). As described above, a secondary battery is understood to be a rechargeable battery that can be discharged when a load is applied and recharged when an external power source is applied. The battery 126 includes one or more battery cells 150 assembled together. Figure 2B As shown, each battery cell 150 generally includes a positive electrode current collector 152, a negative electrode current collector 154, a positive electrode 156, a negative electrode 158, a separator 160, an electrolyte 162, and a capacitor for capturing transition metal ions (e.g., Mn + ) of the zeolite particle layer 164. Although the battery cell 150 shown includes two negative current collectors 154 and one positive current collector 152, the battery cell 150 may alternatively include two positive current collectors 152 and one negative current collector 154, or one positive current collector 152 and one negative current collector 154. In addition, although the zeolite particle layer 164 is disposed on either side of each separator 160 shown, the zeolite particle layer 164 may be disposed on either side of the separator 160, as further described herein. During discharge, when the battery 126 is powering the load 124, the Li + Ions move from the negative electrode 158 through the separator 160 to the positive electrode 156 via the electrolyte 162. - The voltage is transferred from the positive electrode 156 to the negative electrode 158 through the circuit 146 to provide a voltage to the load 124. When charging, when an external voltage is applied, Li + The ions move from the positive electrode 156 to the negative electrode 158 through the electrolyte 162 across the separator 160 and may be intercalated in the negative electrode 158 .

[0040] The positive current collector 152 and the negative current collector 154 are formed of a conductive material. In an embodiment, the positive charge current collector 152 may include one or more of aluminum, nickel, and stainless steel; the negative current collector 154 may include one or more of copper, nickel, stainless steel, and titanium. The current collectors 152, 154 are shown in the form of foils; however, it should be understood that other forms may also be present. The positive current collector 152 and the negative current collector 154 are airtight. In an embodiment, the positive current collector 152 presents a thickness between 5 microns and 50 microns, including all values ​​and ranges therein, such as between 8 microns and 25 microns, and the negative current collector 154 presents a thickness between 5 microns and 50 microns, including all values ​​and ranges therein, such as between 8 microns and 25 microns.

[0041] The positive electrode 156 includes a lithium ion (Li + ) source and can withstand the reversible insertion or embedding of lithium ions, thereby determining the capacity and average voltage of the battery. The positive electrode material includes lithium and a transition metal, such as manganese. In an embodiment, the positive electrode 156 is formed by one or more of LiMeO2, LiMeO4, and LiMePO4, wherein Me is a transition metal, and in some aspects includes manganese alone or in combination with other transition metals (such as nickel and iron). In an embodiment, the positive electrode 156 includes at least one of lithium ion manganese oxide (LMO), lithium manganese nickel oxide (LMNO), lithium-rich manganese oxide (LMR), lithium nickel manganese cobalt oxide and lithium iron manganese phosphate (LFMP) positive electrodes, and other chemicals including transition metals such as cobalt, vanadium, and aluminum. The thickness of the positive electrode 156 is between 50 microns and 150 microns, including all values ​​and ranges therein. In an embodiment, the positive electrode 156 is applied to the positive current collector 152 as a coating using a deposition process (such as a slurry-based process, a hot roller pressing process, extrusion, or additive manufacturing). The combined positive electrode 156 and positive current collector 152 provide a positive electrode, as further referred to herein. In embodiments, the positive electrode has a thickness between 100 microns and 300 microns, including all values ​​and ranges therein.

[0042] The negative electrode 158 includes a material that can undergo reversible insertion or embedding of lithium ions at a lower electrochemical potential than the positive electrode 156 material, so that there is an electrochemical potential difference between the negative electrode 158 and the positive electrode 156. The negative electrode material may include metallic lithium; lithium alloys (such as lithium silicon alloys, lithium aluminum alloys, lithium indium alloys, lithium titanate, and lithium tin alloys); carbon-based materials (such as graphite, activated carbon, carbon black, and graphene); silicon; silicon-based alloys; silicon oxide; silicon-based composite materials; tin oxide; aluminum; indium; zinc; germanium; titanium oxide; and one or more of any combination of the above. In an embodiment, the thickness of the negative electrode 158 is between 50 microns and 150 microns, including all values ​​and ranges therein. In an embodiment, a deposition process, such as a slurry-based process, a hot roll pressing process, extrusion, or additive manufacturing, is used to apply the negative electrode 158 to the negative current collector 154, thereby forming a coating on the negative current collector 154. The combined negative electrode 158 and negative current collector 154 provide a negative electrode, as further referred to herein.

[0043] The separator 160 is a porous material formed of an electrically insulating material that prevents the positive electrode 156 and the negative electrode 158 from contacting and potentially shorting the circuit. The separator 160 is sandwiched or at least partially surrounded between the positive electrode 156 and the negative electrode 158, allowing lithium ions and electrolyte 162 to pass through the pores of the separator 160. The separator 160 may include one or more of a composite material, a polymer material, and a non-woven material. In an embodiment, the separator includes at least one of polyethylene, polypropylene, polyamide, polytetrafluoroethylene, polyvinylidene fluoride, and polyvinyl chloride. In addition, the separator 160 may be filled, that is, including a filler dispersed therein, wherein the filler includes materials such as glass fiber. In additional or alternative embodiments, the separator 160 may include at least one of a thermally stable porous polymer coating and a ceramic coating such as an alumina coating. The coating is disposed on one or more surfaces of a porous polymer film, and the polymer film is selected from at least one of polyethylene and polypropylene. The separator 160 may include one or more layers, wherein each layer is formed by one or more of the above materials. The membrane 160 can be in the form of a film or a mesh, such as a woven mesh or a slit membrane. In an embodiment, the membrane 160 has a thickness between 4 microns and 25 microns, including all values ​​and ranges therein.

[0044] The electrolyte 162 provides a medium between the positive electrode 156 and the negative electrode 158 through which lithium ions and electrolyte move. The medium can be a liquid, a gel, or a solid, and is capable of conducting lithium ions between the positive electrode 156 and the negative electrode 158. The electrolyte 162 penetrates the pores of the porous separator 160 and wets the positive electrode 156 and the negative electrode 158 and the surface of the separator 160. In an embodiment, the electrolyte 162 is a non-aqueous organic solvent. In other embodiments, the electrolyte 162 is a non-aqueous aprotic organic solvent that includes one or more of various alkyl carbonates, such as cyclic carbonates (e.g., ethylene carbonate (EC), propylene carbonate (PC), butylene carbonate (BC), fluoroethylene carbonate (FEC)), linear carbonates (e.g., dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC)), aliphatic carboxylates (e.g., methyl formate, methyl acetate, methyl propionate), γ-lactones (e.g., γ-butyrolactone, γ-valerolactone), chain structure ethers (e.g., 1,2-dimethoxyethane, 1-2-diethoxyethane, ethoxymethoxyethane), cyclic ethers (e.g., tetrahydrofuran, 2-methyltetrahydrofuran, 1,3-dioxolane).

[0045] In any of the above embodiments, the electrolyte 162 may include a lithium salt dissolved in one or more organic solvents. The lithium salt may include one or more of the following: lithium hexafluorophosphate (LiPF6), lithium perchlorate (LiClO4), lithium tetrachloroaluminate (LiAlCl4), lithium iodide (LiI), lithium bromide (LiBr), lithium thiocyanate (LiSCN), lithium tetrafluoroborate (LiBF4), lithium tetraphenylborate (LiB(C6H5)4), lithium bis(oxalate)borate (LiB(C2O4)2) (LiBOB), lithium difluorooxalatoborate (LiBF2(C2O4)), lithium hexafluoroarsenate (LiAsF6), trifluoromethanesulfonate (TFA), lithium tetrafluoroborate (LiBF4), lithium tetraphenylborate (LiB(C6H5)4), lithium tetrafluoroborate (LiB(C2O4)2) (LiBOB), lithium difluorooxalatoborate (LiBF2(C2O4)), lithium hexafluoroarsenate (LiAsF6), lithium trifluoromethanesulfonate (LiBF4), lithium tetrafluoroborate (LiB(C2O4)2), lithium tetrafluoroborate (LiBF2(C2O4)), lithium tetrafluoroarsenate (LiAsF6), lithium tetrafluoromethanesulfonate (LiBF4), lithium tetraphenylborate (LiB(C6H5)4), lithium tetrafluoroborate (LiB(C2O4)2) (LiBOB), lithium difluorooxalatoborate (LiBF2(C2O4)), lithium hexafluoroarsenate (LiAsF6), lithium trifluoromethanesulfonate (LiBF4), lithium tetrafluoroborate (LiBF4), lithium tetraphenylborate (LiB(C6H5)4), lithium tetrafluoroborate (LiB(C2O4)2) (LiBOB), lithium difluorooxalatoborate (LiBF2(C2O4)), lithium hexafluoroarsenate (Li Lithium sulfonate (LiCF3SO3), lithium bis(trifluoromethane)sulfonyl imide (LiN(CF3SO2)2), lithium bis(fluorosulfonyl)imide (LiN(FSO2)2) (LiSFI), lithium (triethylene glycol dimethyl 1 ether) bis(trifluoromethanesulfonyl)imide (Li(G3) (TFSI), lithium bis(trifluoromethanesulfonyl) azide (LiTFSA). The lithium salt may be present in the electrolyte 162 at a concentration (moles of salt per liter of solvent) of 1M to 4M, including all values ​​and ranges therein, such as 2M or 3M.

[0046] Further, the electrolyte 162 may include a variety of additives, such as but not limited to ethylene carbonate, ethylene carbonate, propane sulfonate, and combinations thereof. Other additives may include diluents that do not coordinate with lithium ions but can reduce the viscosity of the electrolyte 162, such as bis (2,2,2-trifluoroethyl) ether (BTFE), and flame retardants, such as triethyl phosphate.

[0047] Figure 3A , 3B 3C shows an embodiment of one or more zeolite particle layers 164 incorporated into the above-mentioned battery cell 150. As described above, the zeolite particles capture transition metal ions released from the positive electrode 156 during lithium ion insertion and deinsertion. In addition to capturing transition metal ions, the zeolite also absorbs moisture that may be present in the battery cell 150. The zeolite particles that provide the zeolite particle layer 164 are generally understood to be microporous, crystalline aluminosilicate materials. The zeolite particles present one or more specific surface areas of more than 100 square meters / gram measured using the BET (Brunauer, Emmett and Teller) theoretical technique, for example in the range of 100 square meters / gram to 500 square meters / gram, including all values ​​and ranges therein. The general formula of zeolite is M n+ 1 / n (AlO2)-(SiO2) x *yH2O, where M n+ 1 / n It is a kind of metal ion, such as lithium ion (Li + ) or hydrogen ion (H +), n is the charge of the metal particles and can be in the range of 1 to 3, x is in the range of 1 to 30, and y is in the range of 1 to 100. In embodiments, the zeolite can exhibit an atomic ratio of Si to Al in the range of 1:1 to 30:1 or greater. In embodiments, the atomic ratio of Si to Al is greater than 5:1 and includes a framework selected from one or more of the following: ASU-7 (ASV), zeolite-Beta (BEA), CIT-5 (CFI), CIT-1 (CON), Deca-dodecasil 3R (DDR), Dodecasil 1H (DOH), UTD-1F (DON), ERS-7 (ESV), EU-1 (EUO), ferrierite (FER), GUS-1 (GON), ITQ-4 (IFR), ITQ-7 (ISV), ITQ-3 (ITE), Levyne (LEV), ZSM-11 (MEL), black gold ore (MEP), ZSM-5 (MFI), ZSM-57 (MFS), MCM-61 (MSO), MCM-35 (MTF), ZSM-39 (MTN), ZSM-23 (MTT), ZSM- The products include: SSZ-12 (MTW), MCM-22 (MWW), nonasil (NON), NU-87 (NES), RUB-17 (RSN), RUB-3 (RTE), RUB-13 (RTH), RUB-10 (RUT), SSZ-48 (SFE), SSZ-44 (SFF), Sigma-2 (SGT), sodalite (SOD), SSZ-35 (STF), SSZ-23 (STT), Terra Nova Ore (TER), Theta-1 (TON), VPI-8 (VET), VPI-9 (VNI), and VPI-7 (VSV).

[0048] like Figure 3A In the embodiment shown, a layer of zeolite particles 164 is applied between the positive electrode 156 and the positive electrode side 168 of the separator 160. In alternative or additional embodiments, as shown Figure 3B As shown, a layer of zeolite particles 164 is applied between the negative electrode 158 and the negative electrode side 170 of the separator 160. In other embodiments, as Figure 3CAs shown, the zeolite particle layer 164 is applied between the positive electrode 156 and the positive electrode side 168 of the separator 160 and between the negative electrode 158 and the negative electrode side 170 of the separator 160. The zeolite particle layer 164 can present a thickness of less than 10 microns, for example, in the range of 0.5 microns to 2 microns, including all values ​​and ranges therein. In various aspects disclosed herein, the zeolite particle layer 164 does not include a polymer binder or other binder, nor does it use a polymer binder or binder to adhere the zeolite particle layer 164 to the surrounding layer. In addition, in the embodiment, the zeolite particle layer 164 can cover the entire or only cover the zeolite particle layer 164 and the positive electrode 156, the negative electrode 158, or the positive electrode 156 and the negative electrode 158. The interface between the negative electrode 158 depends on which two layers the zeolite particle layer 164 is disposed between. In addition, in the embodiment, the zeolite particle layer 164 presents a porosity in the range of 10% to 90% of the total volume defined by the zeolite particle layer 164. Porosity is understood herein as a measure of the volume of void space present in the total volume defined by a given layer, in this case the zeolite particle layer 164. It will be appreciated that if the porosity is too high, e.g., greater than 90%, the effectiveness of the zeolite particle layer 164 is reduced, and if the porosity is too low, e.g., less than 10%, the resistance of the battery cell may be increased, reducing its overall power performance.

[0049] Reference again Figure 2B In an embodiment, the battery cells 150 are separated by separators 160, which may at least partially wrap each battery cell 150. Further, the battery cells 150 are sealed in bags 166 to seal the battery cells 150 to prevent the entry of water and other components that may damage the battery cells 150. In an embodiment, a portion of the positive current collector 152 extends out of the bag 166 and is fixed to the positive electrode tab 172 that connects the positive current collector 152 to the positive bus bar 178. In addition, a portion of the negative current collector 154 extends out of the bag 166 and is fixed to the negative electrode tab 174 connected to the negative bus bar 180. The bus bars 178, 180 are then directly or indirectly connected to the load 148.

[0050] Reference Figure 4 , further reference Figure 5To Figure 7, a method 400 for forming a battery cell 150 including one or more zeolite particle layers 164 is described, which shows a system 500, 600 for manufacturing a battery cell. In order to apply the zeolite particle layer 164 to the battery cell 150, at box 402, the zeolite particles are dispersed in a non-aqueous solvent to form a zeolite dispersion. In an embodiment, the zeolite particles are present in the solvent at 0.1% to 30% by mass of the total mass of the dispersion, including all values ​​and ranges therein. The dispersion of zeolite particles in the solvent can help maintain a relatively low moisture level of the zeolite particles. In an embodiment, the moisture content is less than 550ppm of the total zeolite mass (excluding the solvent mass).

[0051] In embodiments, non-aqueous solvents include organic solvents that present relatively low boiling points, thereby allowing solvents to evaporate at ambient temperature and pressure. In embodiments, solvents include solvents that present 120°C or lower boiling points at standard atmospheric pressure (i.e., 101.3 kPa). In other embodiments, solvents are one or more of methylene chloride, acetone, acetonitrile, ammonia, isopropanol, n-propanol, ethanol, methanol, formic acid, n-butanol, acetic acid, and nitromethane. It is understood that such ambient temperature and pressure can change according to the location where the process is carried out, and the selection of solvents can be adjusted based on the process location.

[0052] In other or alternative embodiments, the solvent is the same material selected for the electrolyte 162 used in the battery cell 150. In an embodiment, the solvent includes one or more non-alkyl organic solvents, including one or more of various alkyl carbonates, such as cyclic carbonates (such as ethylene carbonate (EC), propylene carbonate (PC), butylene carbonate (BC), fluoroethylene carbonate (FEC)), linear carbonates (such as dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC)), aliphatic carboxylates (such as methyl formate, methyl acetate, methyl propionate), γ-lactones (such as γ-butyrolactone, γ-valerolactone), chain structure ethers (such as 1,2-dimethoxyethane, 1-2-diethoxyethane, ethoxymethoxyethane), and cyclic ethers (such as tetrahydrofuran, 2-methyltetrahydrofuran, 1,3-dioxolane). It will be appreciated that when the same solvent as the electrolyte 162 is used, the wetting time of the cell 126, i.e., the time required for the electrolyte 162 to penetrate the separator 160 and wet the surfaces of the positive electrode 156 and the negative electrode 158 after assembly and introduction of the electrolyte 162, can be shortened.

[0053] In any of the above embodiments, the zeolite dispersion may also include a surfactant that reduces the surface tension of the solvent and improves the wettability of the solvent on the surface of the battery cell 150. For example, the surfactant may include lithium dodecyl sulfate (LiD), polyoxyethylene ether, and lithium perfluorooctane sulfonate. In an embodiment, the surfactant is present at 0.1% to 2% by mass of the total mass of the zeolite dispersion, including all values ​​and ranges therein. However, it is worth noting that no adhesive or other adhesive is used in the zeolite dispersion to fix the zeolite particles to the surface of the battery cell 150.

[0054] At block 404, the battery 126 is assembled and the zeolite dispersion is applied to the surface of the battery cell 150 when the battery cell 150 is assembled. The battery cell 150 can be assembled using one or more of several systems that combine a positive electrode including a positive electrode 156 and a positive current collector 152 and a negative electrode including a negative electrode 158 and a negative current collector 154 with a positive electrode 156 and a positive current collector 152. Figure 5 The separator of the z-fold system 500 shown is interlaced, or the positive electrode including the positive electrode 156 and the positive current collector 152 and the negative electrode including the negative electrode 158 and the negative current collector 154 are interlaced with each other. Figure 6 The jelly roll system 600 is shown interleaved. In these processes, when the positive electrode 502, 602 and the negative electrode 504, 604 are assembled into the battery cell 150 together with the separator 506, 606, 160, a zeolite dispersion 510, 610 is applied using a disperser 508, 608. The disperser 508, 608 includes, for example, one or more nozzles located within the assembly system 500, 600.

[0055] For example, in an embodiment, a z-folding system 500 is used to assemble the battery cell 150 . Figure 5 , 7A 7B show an embodiment of the z-folding system 500. During the z-folding process, the positive electrode 502 and the negative electrode 504 are moved from the positive electrode supply source 512 and the negative electrode supply source 514 and are interlaced with the strip-shaped separators 506 and 160. In the embodiment, before the positive electrode 502 is placed on the separators 506 and 160, the zeolite dispersion 510 is dispersed from one or more dispersers 508 in the form of nozzles to form a zeolite particle layer 164 on the surface of the separator 506, which will contact the positive electrode 502. Then, the positive electrode 502 is placed on the separators 506 and 160, and the separators 506 and 160 are wrapped around the positive electrode 502. Then, the negative electrode 504 is placed, and the separator is sandwiched between the positive electrode 502 and the negative electrode 504. Then, the separator 506 is folded back onto the negative electrode 504. This forms a structure similar to Figure 3AThe zeolite arrangement shown. Before placing the positive electrode 502, the zeolite dispersion 510 may not be dispersed, or before placing the negative electrode 504, the zeolite dispersion 510 may be dispersed on the other side of the separator 506, 160 to form a zeolite particle layer 164, thereby forming a similar Figure 3B or Figure 3C The arrangement shown (if the zeolite dispersion is dispersed on both surfaces of the separator 506). The process is then repeated until the desired number of layers of positive electrode 502 and negative electrode 504 are assembled into the battery cell 150. It should be understood that in an embodiment, the zeolite dispersion 510 can be applied once per cycle, for example, just before the positive electrode 502 or the negative electrode 504 is inserted into the z-folded assembly 500. In addition, it is understood that the disperser 508 can be adjusted to apply the zeolite dispersion 510 to a specific location on the separator 506, so that the zeolite dispersion 510 contacts only one surface of the positive electrode 502 or the negative electrode 504.

[0056] In an alternative embodiment, reference Figure 6 , which shows a jelly roll system 600. During the winding process, the positive electrode 602 and the negative electrode 604 are in the form of strips and are unwound from the positive electrode supply source 612 and the negative electrode supply source 614, respectively. The first separator 606 in the form of a strip sandwiched between the positive electrode 602 and the negative electrode 604 is unwound from the first separator supply source 616. A second separator 606 located on either side of the positive electrode 602, the first separator 606 and the negative electrode 604 is also provided, and the second separator 606 is unwound from the second separator supply source 618. Four strips, namely the positive electrode 602, the negative electrode 604 and the two separators 606, are wound on a mandrel 620. The zeolite dispersion 610 is dispersed from one or more dispersers 608 in the form of nozzles between the first separator 606 and the positive electrode 602, between the first separator 606 and the negative electrode 604, or between the first separator 606 and the positive electrode 602, and between the first separator 606 and the negative electrode 604. After dispersing the zeolite dispersion 610, the positive electrode 602, the negative electrode 604, and the separator 606 are contacted together so that the separator 606 and the zeolite particle layer 164 are interlaced between the layers of the positive electrode 602 and the negative electrode 604 in the roll.

[0057] It should be understood that if a low boiling point solvent is selected as the zeolite dispersion solvent, the low boiling point solvent is given time to evaporate from the surface to which it is applied before the zeolite particle layer 164 and the separator 506, 606, 160 are enclosed between the positive electrode 502, 602 and the negative electrode 504, 604 layers. Alternatively or additionally, the solvent can be evaporated by baking the battery cell 150 in an oven at low pressure (e.g., a pressure below standard atmospheric pressure) after assembling the battery cell 150. Alternatively, if the solvent selected for the zeolite dispersion 510, 610 is the same solvent as the electrolyte 162, the process can be performed without waiting for the solvent to evaporate.

[0058] After assembling the positive electrode 502, 602, the negative electrode 504, 604, and the separator 506, 606, the single battery cell 150 is placed in the bag 166. The bag 166 is formed of a non-conductive material, such as a thermoplastic film. In an embodiment, the thermoplastic film includes polyethylene or polypropylene. At block 406, in an embodiment, if necessary, the electrolyte 162 (reference Figure 2B ) is added to the bag 166, and the bag 166 is sealed. Optionally, the bag 166 is stored for later assembly, or assembled in the battery housing 182.

[0059] In the embodiment, the above method 400 can be performed under the conditions of a dew point of minus 40°C and a relative humidity of 1%. In addition, once the positive electrode 502, 602 and the negative electrode 504, 604 are assembled with the separator 506, 606, 160, since the positive current collector 156 and the negative current collector 154 provide a moisture barrier for the zeolite particle layer 164, the ability of moisture to enter the assembly is greatly reduced. After assembly, only the edge of the battery cell 150 is exposed to the environment, and the edge of the battery cell 150 and the zeolite particle layer 164 presents a surface area that is significantly smaller than the interlayer surface of the zeolite particle layer 164.

[0060] The methods and systems herein have many advantages. These advantages include, for example, providing a transition metal ion trap between the positive electrode and the negative electrode to capture dissolved transition metal ions without introducing additional moisture from the battery manufacturing environment. There is no need to use a binder or adhesive to fix the zeolite to the separator, positive electrode and negative electrode before assembling the battery. Other advantages are the use of moisture-proof positive and negative current collectors to prevent moisture from contacting the zeolite during battery assembly. When the same solvent is used in the zeolite dispersion as in the electrolyte, another advantage is that the solvent is able to wet the positive electrode, negative electrode and separator, and may shorten the typical overall wetting time in the process.

[0061] As used herein, the term "controller" and related terms such as microcontroller, control module, module, controller, control unit, processor and similar terms refer to one or more combinations of application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), electronic circuits, central processing units (e.g., microprocessors), and related non-transitory memory components in the form of memory and storage devices (read-only, programmable read-only, random access, hard drives, etc.). The controller 132 may also be composed of multiple controllers that are electrically connected to each other. The controller 132 may be interconnected with additional systems and / or controllers of the vehicle 100, allowing the controller 132 to access data such as the speed, acceleration, braking, and steering angle of the vehicle 100.

[0062] The processor can be a custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor of multiple processors associated with the controller 132, a semiconductor-based microprocessor (in the form of a microchip or chipset), a macroprocessor, a combination thereof, or generally a device for executing instructions.

[0063] The tangible non-transitory memory 134 may include volatile and non-volatile storage devices such as read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables when the processor is powered off. The tangible non-transitory memory 134 may be implemented using a plurality of storage devices such as a PROM (programmable read-only memory), an EPROM (electrical PROM), an EEPROM (electrically erasable PROM), flash memory, or other electrical, magnetic, optical, or combination storage devices capable of storing data, some of which represent executable instructions used by the controller 132 to control various systems of the vehicle 100.

[0064] The description of the present disclosure is merely exemplary in nature, and variations that do not depart from the gist of the present disclosure are intended to fall within the scope of the present disclosure. These variations should not be regarded as departing from the spirit and scope of the present disclosure.

Claims

1. A method for forming a battery cell, comprising: dispersing a plurality of zeolite particles in a non-aqueous solvent to form a zeolite dispersion; Providing a positive electrode and a negative electrode, wherein the positive electrode comprises a positive electrode and a positive electrode current collector, and the negative electrode comprises a negative electrode and a negative electrode current collector; Disposing a porous separator at least partially between the positive electrode and the negative electrode; dispersing the zeolite dispersion between the porous separator and at least one of the positive electrode and the negative electrode; forming a layer of zeolite particles; as well as The porous separator and the zeolite particle layer are sandwiched between the positive electrode and the negative electrode.

2. The method according to claim 1, wherein: The zeolite particles are present in the solvent in an amount of 0.1% to 30% by mass based on the total mass of the zeolite dispersion.

3. The method according to claim 2, wherein: The zeolite dispersion liquid contains a surfactant, and the content of the surfactant is 0.1 mass % to 2 mass % based on the total mass of the zeolite dispersion liquid.

4. The method according to claim 2, wherein: The zeolite dispersion does not contain a polymer binder.

5. The method according to claim 2, wherein: The boiling point of the non-aqueous solvent is lower than 120°C.

6. The method of claim 5, further comprising evaporating the non-aqueous solvent from the zeolite dispersion.

7. The method according to claim 2, wherein: The battery cell is used in a battery, and the battery includes an electrolyte and the nonaqueous solvent is the electrolyte.

8. The method according to claim 2, wherein: Disposing a porous membrane at least partially between the positive electrode and the negative electrode includes interleaving positive electrodes within first pleats of the porous membrane and interleaving negative electrodes within second pleats of the porous membrane.

9. The method according to claim 8, wherein: Dispersing the zeolite dispersion includes spraying the zeolite dispersion on a first side of the porous separator in contact with the positive electrode.

10. A secondary lithium-ion battery cell for a vehicle, comprising: a positive electrode comprising lithium and a transition metal; Negative electrode; a porous separator sandwiched between the positive electrode and the negative electrode; an electrolyte that permeates the porous separator and contacts the positive electrode and the negative electrode; and A zeolite particle layer is located between the porous separator and at least one of the positive electrode and the negative electrode, wherein the zeolite particle layer does not include a binder of the zeolite particle layer in the battery cell.

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