CATHODE WITH ULTRA-CONDUCTIVE ADDITIVE

Abstract

Methods for manufacturing a cathode, methods for manufacturing a battery, and batteries are disclosed. A method for manufacturing a cathode involves mixing a slurry containing a cathode material and an ultraconductive additive with a conductivity of at least 0.25 × 10⁻⁶. 5 Siemens per centimeter (S / cm) includes, and the formation of a cathode from the slurry.

Description

INTRODUCTION

[0001] The technical field generally relates to rechargeable electrochemical devices. More specifically, aspects of this revelation relate to cathodes and methods for manufacturing cathodes on current collectors for the formation of batteries.

[0002] Modern production vehicles, such as the contemporary automobile, are inherently equipped with a powertrain that propels the vehicle and supplies power to its onboard electronics. In automotive applications, for example, a vehicle's powertrain generally consists of a drive motor that transmits the drive torque to the vehicle's final drive system (e.g., differential, axles, camshaft modules, wheels, etc.) via an automatic or manual transmission. Motor vehicles have historically been powered by internal combustion engines with reciprocating pistons because they are readily available, relatively inexpensive, lightweight, and highly efficient. Such engines include compression-ignition (CI) diesel engines, spark-ignition (SI) gasoline engines, two-, four-, and six-stroke engines, and rotary engines, to name just a few.Hybrid electric and fully electric vehicles (collectively referred to as "electric vehicles"), on the other hand, use alternative energy sources to power the vehicle, thus minimizing or eliminating the dependence on an internal combustion engine for traction.

[0003] A fully electric vehicle (FEV), also commonly referred to as an "electric car," is a vehicle configuration with an electric drive system in which the internal combustion engine and its associated peripheral components are completely omitted, and instead a rechargeable energy storage system (RESS) and a traction motor are used to propel the vehicle. Hybrid electric vehicles (HEVs), on the other hand, use multiple drive sources, usually an internal combustion engine in conjunction with a battery- or fuel cell-powered traction motor.

[0004] Many commercially available hybrid and fully electric vehicles have a rechargeable battery pack that stores and supplies the energy required to power the traction motors. To generate traction with sufficient range and speed, a battery pack is significantly larger, more powerful, and has a higher capacity (in amperes) than a standard 12-volt battery used for starting, lighting, and ignition (SLI). For example, in modern traction battery packs, battery cell stacks (e.g., 8–16 cells / stack) are grouped into individual battery modules (e.g., 10–40 modules / pack) that are mounted to the vehicle chassis using a battery pack housing or carrier. Stacked electrochemical battery cells can be connected in series or parallel using an integrated circuit board (ICB) or a front-end DC bus assembly.A specialized electronic battery control module (EBCM), in cooperation with a powertrain control module (PCM) and an inverter module (TPIM), regulates the opening and closing of the battery pack's contactors to control the operation of the battery pack.

[0005] There are four main types of batteries used in electric vehicles: lithium batteries, nickel-metal hydride batteries, ultracapacitor batteries, and lead-acid batteries.

[0006] Besides their use in electric vehicles, high-energy-density electrochemical cells can be used in a variety of consumer products. Typical batteries include a first electrode, a second electrode, an electrolyte, and a separator. One electrode serves as the positive electrode or cathode (during discharge), and the other as the negative electrode or anode (during discharge). A stack of battery cells can be electrically connected to increase the overall power. Conventional rechargeable batteries work by reversibly transferring ions back and forth between the negative and positive electrodes. A separator and an electrolyte are located between the negative and positive electrodes. The electrolyte is capable of conducting ions and can be in solid (e.g., solid-state diffusion) or liquid form.When the battery is charged, the ions move from the cathode (positive electrode) to the anode (negative electrode), and when the battery is discharged, they move in the opposite direction.

[0007] Cathode-active materials typically have low conductivity. Increasing the conductivity of a cathode can result in a battery with higher energy density and a longer lifespan. A certain increase in conductivity can be achieved by including carbon black in the cathode to promote electron flow.

[0008] Accordingly, it would be desirable to provide methods for manufacturing cathodes, methods for manufacturing batteries, and batteries with cathodes exhibiting improved cathode conductivity. Furthermore, other desirable features and properties of the present disclosure will become apparent from the following detailed description and the accompanying claims in conjunction with the accompanying drawings and the preceding introduction. DESCRIPTION

[0009] In one embodiment, a method for producing a cathode is provided and involves mixing a slurry containing a cathode material and an ultraconductive additive with a conductivity of at least 0.25 × 10 5 Siemens per centimeter (S / cm) contains, and the formation of a cathode from the slurry.

[0010] In certain embodiments of the process, the ultraconducting additive is selected from titanium diboride (TiB2), niobium-titanium alloy, germanium-niobium alloy and niobium nitride alloy, yttrium barium copper oxide ceramic (YBCO), magnesium diboride ceramic, superconducting pnictides and organic superconductors.

[0011] In certain embodiments of the process, the ultraconductive additive is chemically inert.

[0012] In certain embodiments of the process, the ultraconductive additive is titanium diboride (TiB2).

[0013] In certain embodiments of the method, the cathode contains 0.1 to 10 percent by weight of the titanium diboride, based on the total weight of the cathode.

[0014] In certain embodiments of the method, the cathode contains 1 to 5 percent by weight of the titanium diboride, based on the total weight of the cathode.

[0015] In certain embodiments of the method, forming the cathode from the slurry involves coating a collector with a layer of the slurry, wherein the layer has a uniform consistency of cathode material and titanium diboride.

[0016] In certain embodiments, the method also includes calendering the layer to reduce the layer thickness.

[0017] In certain embodiments of the process, the ultraconductive additive is in the form of particles with a particle thickness of five nanometers to three micrometers.

[0018] In certain embodiments of the process, the mixing, formation and calendering processes are carried out at a temperature of no more than 200 degrees Celsius.

[0019] In certain embodiments of the process, the slurry also includes soot and binders.

[0020] In certain embodiments of the process, the cathode material includes nickel (Ni), cobalt (Co), manganese (Mn) and aluminum (Al).

[0021] In certain embodiments of the process, the process does not include a thermal tempering process.

[0022] In another embodiment, a method for manufacturing a battery is provided and includes forming an anode; forming a cathode by coating a collector with a slurry containing a cathode material and an ultraconductive additive with a conductivity of at least 0.25 × 10 5 Siemens per centimeter (S / cm) includes; the separation of the anode from a cathode with a separator; and the contacting of the anode and the cathode with an electrolyte.

[0023] In certain embodiments of the method, the ultraconductive additive is titanium diboride (TiB2), and wherein the cathode contains 0.1 to 10 percent by weight of the titanium diboride, based on a total weight of the cathode.

[0024] In certain embodiments of the process, the cathode contains 0.1 to 10 percent carbon black by weight, based on the total weight of the cathode.

[0025] In another embodiment, a battery is provided and includes an anode current collector; an anode-active material that is in direct contact with the anode current collector; a cathode current collector; a cathode layer that is in direct contact with the cathode current collector, wherein the cathode layer is a uniform mixture of a cathode-active material and an ultraconductive additive having a conductivity of at least 0.25 × 10 5Siemens per centimeter (S / cm); a separator between the anode-active material and the cathode layer; and an electrolyte in contact with the anode-active material and the cathode layer.

[0026] In certain battery designs, the ultraconductive additive is titanium diboride (TiB2).

[0027] In certain embodiments of the battery, the cathode layer contains 0.1 to 10 percent by weight of titanium diboride; 0.1 to 10 percent by weight of carbon black; and at least 75 percent by weight of the cathode-active material, each based on the total weight of the cathode layer.

[0028] In certain embodiments of the battery, the cathode layer comprises 1 to 5 wt. percent titanium diboride; 1 to 5 wt. percent carbon black; 1 to 5 wt. percent of a binder material; and at least 90 wt. percent of the cathode-active material, all based on the total weight of the cathode layer. DESCRIPTION OF THE DRAWINGS

[0029] The present disclosure is described below in conjunction with the following drawings, where identical numbers denote identical elements and where: Fig. 1 a schematic explanation of a representative vehicle with an electrified powertrain according to aspects of the disclosed concepts; Fig. 2. A schematic explanation of a representative electrochemical device in the vehicle of Fig. 1 is, which operates in accordance with aspects of the present revelation; Fig. 3 is a flowchart that presents a process for manufacturing a cathode and for manufacturing a battery in accordance with the aspects of the present disclosure; and Fig. 4 is a schematic cross-sectional representation of a cathode formed on a collector in accordance with aspects of the present disclosure. DETAILED DESCRIPTION

[0030] The following detailed description is merely exemplary and is not intended to limit the application and use of the embodiments described herein. Furthermore, there is no intention to be bound by any express or implied theory set forth in the preceding introduction, summary, or the following detailed description. As used herein, the term "module" refers to any hardware, software, firmware, electronic control unit or component, processing logic, and / or processing device, individually or in any combination, including, but not limited to: application-specific integrated circuits (ASICs), electronic circuits, processors (common, dedicated, or grouped) and memory executing one or more software or firmware programs, combinational logic circuits, and / or other suitable components providing the described functionality.

[0031] Embodiments of the present disclosure can be described here in the form of functional and / or logical block components and various processing steps. It should be noted that such block components can be implemented by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, an embodiment of the present disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, or the like, which can perform a variety of functions under the control of one or more microprocessors or other control devices.Furthermore, the person skilled in the art will recognize that embodiments of the present disclosure can be used in conjunction with any number of automated driving systems, including cruise control systems, automated driver assistance systems and autonomous driving systems, and that the vehicle system described here is merely an exemplary embodiment of the present disclosure.

[0032] For the sake of brevity, conventional techniques and components relating to the mechanical parts of the vehicle and other functional aspects of the system (and the individual operating components of the system) cannot be described in detail here. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and / or physical connections between the different elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in an embodiment. The figures are for illustrative purposes only and may not be drawn to scale.

[0033] Furthermore, the following description refers to elements or features being "connected" or "coupled" to one another. As used here, "connected" can refer to an element / component that is directly connected to (or directly associated with) another element / component, not necessarily mechanically. Likewise, "coupled" can refer to an element / component that is directly or indirectly connected to (or directly or indirectly associated with) another element / component, not necessarily mechanically. However, it should be understood that although two elements may be described as "connected" in one embodiment below, similar elements may be "coupled" in alternative embodiments, and vice versa.Although the schematic representations shown here depict exemplary arrangements of elements, an actual embodiment may include additional intermediate elements, devices, features or components.

[0034] An exemplary battery, a method for making a cathode, and a method for making a battery are provided to increase the conductivity of cathodes.

[0035] Certain embodiments provide a means of developing and manufacturing a cathode with improved energy density and cycle life by incorporating ultraconductive additives (UCAs) into the cathode during the slurry mixing process. For example, titanium diboride (TiB2) is an ultraconductive additive that exhibits more than 1000 times the electronic conductivity of conductive carbon black. In certain embodiments, the addition of a small amount of TiB2 to the cathode material, for example, 1 to 5 percent by weight (based on the total weight of the cathode), results in a higher energy density and longer cycle life. In certain embodiments, the ultraconductive additive added to the cathode-active material is chemically inert. For example, TiB2 is chemically inert in the battery environment.

[0036] In certain embodiments, the ultraconducting additive is mixed into a slurry of the cathode-active material. This slurry can then be applied to a conductor. The layer of slurry applied to the conductor can be dried and / or calendered to reduce its thickness. It is worth noting that the cathode material layer is essentially uniform, ensuring that the amount of ultraconducting additive is evenly distributed throughout the entire layer. This differs from laminations or separate material layers, which can entail additional processing steps and costs while yielding less effective results.

[0037] While the cathode-active material is not limited to such embodiments, it contains nickel in certain embodiments. The cathode-active material can, for example, be NCMA, i.e., nickel (Ni), cobalt (Co), manganese (Mn), and aluminum (Al). Mixing TiB2 with NCMA in the slurry mixing process can significantly improve the electrochemical performance of the electrode formed from the slurry.

[0038] In certain embodiments, the ultraconducting additives may include: TiB2 in the form of nanoparticles, nanofibers, nanoflakes or other similar forms; alloys such as niobium-titanium, germanium-niobium and / or niobium nitride; ceramics such as yttrium barium copper oxide (YBCO) and / or magnesium diboride; superconducting pnictides such as the fluorine-doped iron-based layer compound LaOFeAs; or organic superconductors such as fullerenes.

[0039] In certain embodiments, a cathode is produced by mixing the active cathode material, e.g., a nickel-containing material, with ultraconducting additives in a slurry. For example, 0.1 to 10 wt% TiB₂ can be added to the cathode slurry and thoroughly mixed at 500–3000 rpm for two to ten minutes. The mixer can include a planetary, high-speed, acoustic, or static mixer, an extruder, and a dissolver. The size of the TiB₂ particles can range from five nanometers (nm) to three micrometers (µm).

[0040] With reference to Fig. Figure 1 represents certain characteristics of a vehicle 10 in the form of a function block diagram. In certain examples, the vehicle 10 comprises an automobile. In other examples, the vehicle 10 can be any one of a range of different types of automobiles, such as a sedan, a station wagon, a truck, or a sport utility vehicle (SUV), and can have two-wheel drive (2WD) (i.e., rear-wheel drive or front-wheel drive), four-wheel drive (4WD), or all-wheel drive (AWD), and / or various other types of vehicles or mobile platforms in certain examples.

[0041] The depicted vehicle 10 is merely an exemplary application with which new aspects of this disclosure can be put into practice. Likewise, the incorporation of the present concepts into a fully electric vehicle powertrain should be recognized as a non-limiting implementation of the disclosed features. As such, it is self-evident that aspects and features of this disclosure can be applied to other powertrain architectures, implemented for any logically relevant vehicle type, and used for both DC and AC-based EVCS. Furthermore, only selected components of the motor vehicles and battery systems are shown and described in detail here.Nevertheless, the vehicles and vehicle systems discussed below may include numerous additional and alternative features as well as other available peripheral components to perform the various procedures and functions of this disclosure.

[0042] As in Fig. As shown in Figure 1, the example vehicle 10 generally comprises a body 14 and wheels 16. The body 14 essentially encloses the components of the vehicle 10. The wheels 16 are rotatably coupled to the vehicle 10 near each corner of the body 14.

[0043] The representative vehicle 10 of Fig. 1 can be equipped with an electrified powertrain capable of providing and supplying tractive torque to one or more wheels 16 of the vehicle. The powertrain is in Fig. 1 is generally represented by a rechargeable energy storage system (RESS), which may be in the form of a chassis-mounted traction battery pack 70 functionally connected to an electric traction motor 40. The traction battery pack 70 generally consists of one or more battery modules 72, each containing a stack of battery cells 110, such as pocket, can, or prismatic lithium-ion, lithium-polymer, or nickel-metal hydride battery cells. One or more electric machines, such as traction motors / generator units 40, draw electrical energy from the battery pack 70 of the RESS and optionally also supply it. A dedicated inverter module (PIM) can electrically connect the battery pack 70 to the motor / generator unit(s) 40 and modulate the transfer of electrical current between them.

[0044] The battery pack 70 can be configured so that module management, including cell scanning, thermal management, and module-to-host communication functions, is integrated directly into each battery module 72 and communicates wirelessly via a wireless cell monitoring unit (CMU). The CMU can be a microcontroller-based sensor array mounted on a printed circuit board (PCB). Each CMU can be equipped with a GPS transceiver and RF capabilities and can be located on or inside a battery module housing. The cells of the battery module 110, the CMU, the housing, the coolant lines, the busbars, etc., together form the module assembly.

[0045] In Fig. Figure 2 shows an exemplary electrochemical device in the form of a rechargeable battery 110, which provides a desired electrical load, such as the vehicle 10. Fig. 1, powered and offering fast-charging capabilities, such as DCFC. The battery 110 includes a pair of electrically conductive electrodes, namely a first (negative or anode) working electrode 122 and a second (positive or cathode) working electrode 124, which are housed in an outer protective casing 120. At least in some configurations, the battery casing 120 can be a sleeve-like bag formed from aluminum foil or another suitable foil material. Both sides of a metallic bag can be provided with a polymer coating to insulate the metal from the internal cell elements and, if applicable, from adjacent cells. Alternatively, the battery casing (or “cell case”) 120 can take a cylindrical metal can shape, i.e., for cylindrical battery cell configurations, or a polyhedral metal box shape, i.e., for prismatic battery cell configurations.Referring to one of the two working electrodes 122, 124 as "anode" or "cathode" or, in this context, as "positive" or "negative," does not restrict the electrodes 122, 124 to a specific polarity, since the system polarity can change depending on whether the battery 110 is operating in a charging or discharging mode. Although in . Fig. Figure 2 shows a single battery cell unit inserted into the battery housing 120; it should be recognized that the housing 120 can accommodate a stack of several cell units (e.g., five to five thousand cells or more).

[0046] With further reference to Fig. 2. The anode electrode 122 can be manufactured with an active anode electrode material capable of trapping ions during a battery charging process and releasing ions during a battery discharging process. In at least some implementations, the anode electrode 122 is made entirely or partially from a lithium metal, e.g., lithium-aluminum (LiAl) alloy materials with a Li / Al atomic ratio in the range of 0 atomic% ≤ Li / Al < 70 atomic% and / or aluminum alloys with an Al atomic ratio > 50 atomic% (e.g., by melting the lithium metal). Other examples of suitable active anode electrode materials include carbon-containing materials (e.g., graphite, hard carbon, soft carbon, etc.), silicon, silicon-carbon composites (silicon-graphite composites), and Li₄Ti₅O₄. 12 , transition metals (alloy types, e.g. Sn), metal oxides / sulfides (e.g. SnO2, FeS and similar) etc.

[0047] Inside the battery casing 120, between the two electrodes 122 and 124, is a porous separator 126, which can be configured as a microporous or nanoporous polymeric separator. The porous separator 126 can contain a non-aqueous liquid electrolyte composition and / or a solid electrolyte composition, collectively referred to as 130, which can also be present in the negative electrode 122 and the positive electrode 124. A negative electrode current collector 132 can be positioned at or near the negative electrode 122, and a positive electrode current collector 134 can be positioned at or near the positive electrode 124. The negative electrode current collector 132 and the positive electrode current collector 134 each collect free electrons and transport them to and from an external circuit 140.An interruptible external circuit 140 with a load 142 is connected to the negative electrode 122 via its respective current collector 132 and electrode tongue 136, and to the positive electrode 124 via its respective current collector 134 and electrode tongue 138. The current collectors 132 and 134 can be made of aluminum, copper, or another suitable material. The separator 126 can be a film-like structure consisting of a porous polyolefin membrane, e.g., with a porosity of about 35% to 65% and a thickness of about 25–30 microns. Electrically non-conductive ceramic particles (e.g., silicon dioxide) can be applied to the porous membrane surfaces of the separators 126.

[0048] The porous separator 126 can function as both an electrical insulator and a mechanical support structure by being inserted between the two electrodes 122, 124 to prevent the electrodes from coming into physical contact and thus causing a short circuit. In addition to providing a physical barrier between the electrodes 122, 124, the porous separator 126 can provide a minimal resistance path for the internal passage of ions (and associated anions) during the ion cycle, thereby facilitating the operation of the battery 110. In some optional configurations, the porous separator 126 can be a microporous polymeric separator incorporating a polyolefin. The polyolefin can be a homopolymer derived from a single monomer component or a heteropolymer derived from more than one monomer component and can be either linear or branched.In a solid-state battery, the role of the separator can be partially / completely provided by a solid electrolyte layer.

[0049] When operating as a rechargeable energy storage system (RESS), the battery 110 generates electrical current, which is transferred to one or more loads 142 that are functionally connected to the external circuit 140. While the load 142 can be any number of electrically powered devices, some non-restrictive examples of power-consuming load devices include an electric motor for a hybrid or fully electric vehicle, a laptop or tablet computer, a mobile phone, cordless power tools and equipment, portable power stations, etc. The battery 110 may include a variety of other components, which are not shown here for the sake of simplicity and brevity, but are nevertheless readily available. For example, the battery 110 may include one or more seals, terminal caps, tongues, battery posts, and other commercially available components or materials that may be located on or within the battery 110.Furthermore, the size, shape, and operating characteristics of the 110 battery may vary depending on the specific application for which it is intended.

[0050] The cathode electrode 124 can be manufactured with an active cathode electrode material capable of supplying ions during a battery charging process and trapping ions during a battery discharging process. The material of the cathode electrode 124 can, for example, include lithium transition metal oxide, phosphate, or silicate, such as LiMO₂ (M = Co, Ni, Mn, or combinations thereof); LiM₂O₄ (M = Mn, Ti, or combinations thereof); LiMPO₄ (M = Fe, Mn, Co, or combinations thereof); and LiM x M' 2-xO4 (M, M' = Mn or Ni). Other examples of suitable active cathode electrode materials include lithium nickel cobalt manganese oxide (NCM), lithium nickel cobalt aluminum oxide (NCA), lithium nickel cobalt manganese aluminum oxide (NCMA), and other lithium transition metal oxides.

[0051] In the present embodiments, the second (positive or cathode) working electrode 124 also includes an ultraconducting additive. For the present purpose, an “ultraconducting additive” has a conductivity of at least 0.25 × 10⁻⁶. 5 Siemens per centimeter (S / cm). In certain embodiments, the ultraconductive additive has a conductivity of at least 0.3 × 10⁻⁶. 5 S / cm, at least 0.4 × 10 5 S / cm, at least 0.45 × 10 5 S / cm, at least 0.5 × 10 5 S / cm, at least 0.51 × 10 5 S / cm, at least 0.52 × 10 5 S / cm, at least 0.53 × 10 5 S / cm, at least 0.54 × 10 5S / cm, at least 0.55 × 10 5 S / cm, at least 0.56 × 10 5 S / cm, at least 0.57 × 10 5 S / cm, at least 0.58 × 10 5 S / cm, at least 0.59 × 10 5 S / cm, at least 0.6 × 10 5 S / cm, at least 0.7 × 10 5 S / cm, at least 0.8 × 10 5 S / cm, at least 0.9 × 10 5 S / cm, at least 1.0 × 10 5 S / cm, or at least 1.1 × 10 5 S / cm. In certain embodiments, the ultraconductive additive exhibits a conductivity of at most 1.0 × 10 6 S / cm on.

[0052] The ultraconducting additive can be selected from titanium diboride (TiB2), e.g., in the form of nanoparticles, nanofibers, nanoflakes, or other suitable forms; alloys such as niobium-titanium, germanium-niobium, and / or niobium nitride; ceramics such as yttrium barium copper oxide (YBCO) and / or magnesium diboride; superconducting pnictides such as the fluorine-doped iron-based layer compound LaOFeAs; or organic superconductors such as fullerenes. It is noted that titanium diboride (TiB2) has an electrical conductivity of 0.599 × 10⁻⁶ Ω·m. 5 up to 1.11 × 10 5 exhibits S / cm.

[0053] In certain embodiments, the ultraconductive additive is chemically inert in the environment of the battery 110. As used here, “chemically inert” means that the species does not undergo any chemical reaction when exposed to other compounds, chemicals, or solutions in the battery 110, or when exposed to electromagnetic radiation or temperatures that occur during typical operation of the battery 110.

[0054] In certain embodiments, the ultraconducting additive is titanium diboride (TiB2) in the form of particles with a particle size or thickness of five nanometers to three micrometers.

[0055] In certain embodiments, the cathode electrode 124 contains from 0.1 to 10 wt% of the ultraconducting additive, based on the total weight of the cathode electrode 124. For example, the cathode electrode 124 may contain at least 0.1 wt% of the ultraconducting additive based on a total weight of the cathode electrode 124, such as at least 0.2 wt%; at least 0.3 wt%; at least 0.4 wt%; at least 0.5 wt%; at least 0.6 wt%; at least 0.7 wt%; at least 0.8 wt%; at least 0.9 wt%; at least 1.0 wt%; at least 1.1 wt%; at least 1.2 wt%; at least 1.3 wt%; at least 1.4 wt%; at least 1.5 wt%; at least 1.6 wt%; at least 1.7 wt%; at least 1.8 wt%; at least 1.9% by weight; at least 2.0% by weight; at least 2.1% by weight; at least 2.2% by weight; at least 2.3% by weight; at least 2.4% by weight; at least 2.5% by weight; at least 2.6% by weight; at least 2.7% by weight-%; at least 2.8 wt%; at least 2.9 wt%; at least 3.0 wt%; at least 3.2 wt%; at least 3.4 wt%; at least 3.6 wt%; at least 3.8 wt%; at least 4.0 wt%; at least 4.2 wt%; at least 4.4 wt%; at least 4.6 wt%; at least 4.8 wt%; at least 5.0 wt%; at least 5.2 wt%; at least 5.4 wt%; at least 5.6 wt%; at least 5.8 wt%; at least 6.0 wt%; at least 6.2 wt%; at least 6.4 wt%; at least 6.6 wt%; at least 6.8 wt%; at least 7.0 wt%; at least 7.2 wt%; at least 7.4 wt%; at least 7.6 wt%; at least 7.8 wt%; at least 8.0 wt%; at least 8.2% by weight; at least 8.4% by weight; at least 8.6% by weight; at least 8.8% by weight; at least 9.0% by weight; at least 9.2% by weight; at least 9.4% by weight; at least 9.6% by weight; or at least 9.8% by weight of the ultraconductive additive, based on a total weight of the cathode electrode 124.

[0056] In certain embodiments, the cathode electrode 124 contains at most 0.3 wt%; at most 0.4 wt%; at most 0.5 wt%; at most 0.6 wt%; at most 0.7 wt%; at most 0.8 wt%; at most 0.9 wt%; at most 1.0 wt%; at most 1.1 wt%; at most 1.2 wt%; at most 1.3 wt%; at most 1.4 wt%; at most 1.5 wt%; at most 1.6 wt%; at most 1.7 wt%; at most 1.8 wt%; at most 1.9 wt%; at most 2.0 wt%; at most 2.1 wt%; at most 2.2 wt%; at most 2.3 wt%; at most 2.4 wt%; at most 2.5 wt%; at most 2.6 wt%; at most 2.7 wt.%; at most 2.8 wt.%; at most 2.9 wt.%; at most 3.0 wt.%; at most 3.2 wt.%; at most 3.4 wt.%; at most 3.6 wt.%; at most 3.8 wt.%; at most 4.0 wt.%; at most 4.2 wt.%; at most 4.4 wt.%; at most 4.6 wt.%; at most 4.8% by weight; maximum 5.0% by weight; maximum 5.2% by weight; maximum 5.4% by weight; maximum 5.6% by weight; maximum 5.8% by weight; maximum 6.0% by weight; maximum 6.2% by weight; maximum 6.4% by weight; maximum 6.6% by weight; maximum 6.8% by weight; maximum 7.0% by weight; maximum 7.2% by weight; maximum 7.4% by weight; maximum 7.6% by weight; maximum 7.8% by weight; maximum 8.0% by weight; maximum 8.2% by weight; maximum 8.4% by weight; maximum 8.6% by weight; maximum 8.8% by weight; maximum 9.0% by weight; maximum 9.2% by weight; maximum 9.4% by weight; maximum 9.6% by weight; at most 9.8 percent by weight; or at most 10 percent by weight of the ultraconducting additive, based on the total weight of the cathode electrode 124. For example, the cathode electrode 124 may contain from 1 to 5 percent by weight of the ultraconducting additive, based on the total weight of the cathode electrode 124.

[0057] In certain embodiments, the cathode electrode 124 includes, in addition to the active cathode electrode material and the ultraconductive additive, also carbon black and a binder material.

[0058] In certain embodiments, the binding material is selected from styrene-butadiene rubber, acrylated styrene-butadiene rubber, acrylonitrile copolymer, acrylonitrile-butadiene rubber, nitrile-butadiene rubber, acrylonitrile-styrene-butadiene copolymer, acrylic rubber, butyl rubber, fluororubber, polytetrafluoroethylene, polyethylene, polypropylene, ethylene / propylene copolymers, polybutadiene, polyethylene oxide, chlorosulfonated polyethylene, polyvinylpyrrolidone, polyvinylpyridine, polyvinyl alcohol, polyvinyl acetate, polyepichlorohydrin, polyphosphazene, polyacrylonitrile, polystyrene, latex, acrylic resins, phenolic resins, epoxy resins, carboxymethylcellulose, hydroxypropylcellulose, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethylcellulose, cyanoethyl sucrose, polyester. Polyamide, polyether, polyimide, polycarboxylate, polycarboxylic acid, polyacrylic acid, polyacrylate, polymethacrylic acid, polymethacrylate, polyacrylamide, polyurethane, fluorinated polymer, chlorinated polymerPolyvinylidene fluoride, poly(vinylidene fluoride)-hexafluoropropene and combinations thereof.

[0059] In certain embodiments, the cathode electrode 124 contains from 0.1 to 10 percent by weight of carbon black, based on the total weight of the cathode electrode 124. For example, the cathode electrode 124 may contain at least 0.1, at least 0.25, at least 0.5, at least 0.75, at least 1, at least 1.5, at least 2, at least 2.5, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8 or at least 9 percent by weight of carbon black, based on the total weight of the cathode electrode 124. Furthermore, the cathode electrode 124 may contain at most 0.25, at most 0.5, at most 0.75, at most 1, at most 1.5, at most 2, at most 2.5, at most 3, at most 4, at most 5, at most 6, at most 7, at most 8, at most 9 or at most 10 percent by weight of soot, based on the total weight of the cathode electrode 124.

[0060] In certain embodiments, the cathode electrode 124 comprises between 70 and 99 percent by weight of the active cathode electrode material. For example, the cathode electrode 124 may comprise at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 percent by weight of the active cathode electrode material, based on the total weight of the cathode electrode 124. Furthermore, the cathode electrode 124 may comprise at most 75, at most 80, at most 85, at most 90, at most 95, or at most 99 percent by weight of the active cathode electrode material, based on the total weight of the cathode electrode 124.

[0061] Fig. Figure 3 is a flowchart illustrating process 300 for manufacturing a cathode. In step 305, process 300 involves the formation of a slurry containing active cathode material. The slurry may also contain carbon black, a binder, and a solvent.

[0062] In 315, process 300 involves adding an ultraconducting additive to the slurry. In 325, process 300 involves mixing the slurry. For example, after adding the ultraconducting additive, the slurry can be mixed for two to ten minutes at a speed of 500 to 3000 rpm. The mixer can include a planetary, high-speed, acoustic, or static mixer, an extruder, or a dissolver. After mixing, the slurry is a homogeneous mixture; that is, the slurry has a substantially homogeneous consistency. In other words, the ultraconducting additive is evenly distributed throughout the slurry.

[0063] After the formation of a homogeneous slurry, the process 300 continues at 335 with the application of a layer of the slurry onto a conductive collector 134. The layer of slurry forms the cathode electrode 124.

[0064] At 345, the 300 process dries the slurry layer. During the drying process, the slurry temperature is kept at no more than 200 degrees Celsius.

[0065] In process 300, the slurry layer is calendered in step 355. During calendering, the slurry temperature is maintained at no more than 200 degrees Celsius. After calendering, the layer processing is complete, and the cathode electrode 124 is formed. Therefore, process 300 can be considered to include the formation of the cathode from the slurry in step 330, encompassing the layer application, drying, and calendering processes 335, 345, and 355.

[0066] After the formation of the cathode electrode 124, the process 300 at 365 continues with the assembly of the battery 110 and its cells. For example, the cathode electrode 124 and the collector 134 can be positioned in the battery housing 120 and separated from the anode electrode 122 and the current collector 132 by a porous separator 126 and are in contact with the electrolyte composition 130.

[0067] The procedure 300 at 375 can then involve performing a cycle of charging and discharging procedures. After that, the procedure 300 can involve operating a device, e.g., vehicle 10, with power from the battery.

[0068] Fig.Figure 4 provides a schematic cross-sectional view of a cathode electrode 124 on a current collector 134. As shown, the cathode electrode 124 includes cathode material particles 401 and ultraconductive additive particles 402. The cathode electrode 124 may also contain other particles, including carbon black and binders.

[0069] As shown, the cathode electrode 124 has a homogeneous consistency. In particular, every region of the cathode electrode 124 contains the same ratio of ultraconducting additive particles 402. In other words, no region of the cathode electrode 124 has fewer ultraconducting additive particles 402, and no region of the cathode electrode 124 has a greater number of ultraconducting additive particles 402.

[0070] Accordingly, in the present embodiments, an increase in the electrical conductivity of a cathode is provided by incorporating an ultraconductive additive into the slurry that forms the cathode.

[0071] Although at least one exemplary embodiment has been presented in the preceding summary and detailed description, it should be acknowledged that a large number of variations exist. It is also understood that the exemplary embodiment or embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the preceding summary and detailed description will provide the person skilled in the art with a practical roadmap for implementing the exemplary embodiment or embodiments. It is understood that various modifications in the function and arrangement of elements may be made without deviating from the scope of the disclosure as set forth in the appended claims and their legal equivalents.

Claims

[1] Method for producing a cathode, the method comprising: Mixing a slurry containing a cathode material and an ultraconductive additive with a conductivity of at least 0.25 × 10 5 Siemens per centimeter (S / cm) includes; and Formation of the cathode from the slurry. [2] Method according to claim 1, wherein the ultraconducting additive is selected from titanium diboride (TiB2); niobium-titanium alloy; germanium-niobium alloy and niobium-nitride alloy; yttrium-barium-copper oxide (YBCO) ceramic; magnesium diboride ceramic; superconducting pnictides; and organic superconductors. [3] Method according to claim 2, wherein the ultraconductive additive is chemically inert. [4] Method according to claim 1, wherein the ultraconductive additive is titanium diboride (TiB2). [5] Method according to claim 4, wherein the cathode comprises 0.1 to 10 wt.% of the titanium diboride, based on the total weight of the cathode. [6] Method according to claim 1, wherein: The formation of the cathode from the slurry includes coating a current collector with a layer of the slurry; the layer has a uniform consistency of the cathode material and the titanium diboride; The process further includes calendering the layer to reduce its thickness; and The mixing, forming and calendering processes are carried out at a temperature of no more than 200 degrees Celsius. [7] Battery, comprising: an anode current collector; an anode-active material that is in direct contact with the anode current collector; a cathode current collector; a cathode layer that is in direct contact with the cathode current collector, wherein the cathode layer is a uniform mixture of a cathode-active material and an ultraconductive additive with a conductivity of at least 0.25 × 10 5 Siemens per centimeter (S / cm) includes; a separator between the cathode-active material and the cathode layer; and an electrolyte that is in contact with the cathode-active material and the cathode layer. [8] Battery according to claim 7, wherein the ultraconductive additive is titanium diboride (TiB2). [9] Battery according to claim 8, wherein the cathode layer comprises: from 0.1 to 10 percent by weight titanium diboride; from 0.1 to 10 percent by weight of soot; and at least 75 percent by weight of the cathode-active material, based on the total weight of the cathode layer. [10] Battery according to claim 9, wherein the cathode layer comprises: from 1 to 5 percent by weight titanium diboride; from 1 to 5 percent by weight of soot; and 1 to 5 percent by weight of a binder; and at least 90 percent by weight of the cathode-active material, each based on the total weight of the cathode layer.

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