Anode electrode for a battery cell

Abstract

An anode electrode for a battery cell, a battery cell, and a method for forming an anode-supported electrolyte separator. The anode electrode comprises an anode current collector with a first surface and an anode-supported electrolyte separator arranged on the first surface. The anode-supported electrolyte separator comprises at least one electrolyte selected from the following compositions: a) yLi₂S·(100-yx)P₂S₅xP₂O₅, where y is in the range of 70 mol percent to 80 mol percent and x is in the range of 1 mol percent to 10 mol percent; b) Li 10 MP2S 12 where M is at least one of Si, Ge and Sn, and c) argyrodite. Furthermore, the anode-supported electrolyte separator has a thickness in the range of 1 micrometer to 100 micrometers.

Description

[0001] Electric and hybrid electric vehicle technology is enabled by the development and use of rechargeable secondary batteries that supply energy to the vehicle's powertrain. Secondary batteries are lithium-ion batteries, which generally contain one or more battery cells, each with a cathode, an anode, a separator, and an electrolyte. The cathode provides the source of lithium ions and determines the battery's capacity and average voltage. The anode stores the lithium ions absorbed by the cathode and releases them when energy is needed. The separator, usually a polymer film or foil, prevents the cathode and anode from touching and short-circuiting the battery, and the electrolyte provides a medium between the cathode and anode through which the lithium ions migrate.In some systems, a solid electrolyte can be used instead of a separator; that is, a solid material that is an ion conductor, in particular a lithium-ion conductor, which also blocks the passage of electrons and prevents short-circuiting of the battery cell. Using a solid electrolyte as a separator can also eliminate the need for a separate electrolyte.

[0002] Lithium-ion batteries are typically assembled by stacking a cathode, a self-supporting separator, and an anode on top of each other, placing the stack in a package to form a battery cell, adding an electrolyte to the battery cell, and connecting multiple battery cells together. Self-supporting separators are typically 100 micrometers thick or more. Reducing the thickness of these separators improves the energy density of the battery cells. However, reducing the separator's thickness can also decrease its ability to be self-supporting.

[0003] To reduce the thickness of the separator and the battery cell, efforts have been made to deposit the separator directly onto the anode or cathode and to use a solid-state electrolyte as the separator. However, lithium metal anodes are generally incompatible with the casting process commonly used to deposit the separator onto the anode. Cathode-supported separators are more compatible with the casting process for depositing a separator onto the cathode. Furthermore, cathode separators have a thickness in the range of 20 to 50 micrometers. However, the anode typically has a relatively larger surface area than the cathode, resulting in the anode protruding beyond the cathode. With such a design, there is a risk of edge short circuits, as the anode overhang can come into contact with the cathode.While one solution is to increase the surface area of ​​the cathode, it is desirable to develop a separator that can be applied directly to the anode.

[0004] US 2017 / 0324113A1 describes negative electrode assemblies with lithium sulfide anolite layers, electrochemical cells with these assemblies, and methods for their fabrication. An anolite layer can be placed over a metal layer of a current collector and serves to separate the current collector from the rest of the electrolyte. The metal layer can contain copper or another suitable metal that forms a metal sulfide in situ during the fabrication of the electrode assembly. Specifically, a sulfur-containing layer, such as a solid electrolyte, is formed on the metal layer. The sulfur from this layer reacts with the metal of the current collector to form a metal sulfide layer. When lithium is subsequently added to the metal sulfide layer, a lithium sulfide anolyte layer is formed, while the metal layer is recovered.Most, if not all, of the processes can be carried out in situ during the manufacture of the electrochemical cells.

[0005] US 2023 / 0155167A1 describes a subassembly consisting of a negative electrode and a solid electrolyte for a fully solid secondary battery, wherein the subassembly comprises: a current collector for the negative electrode; a first negative active material layer on the current collector; an intermediate layer on the first negative active material layer;and a solid electrolyte on the intermediate layer and opposite the first negative active material layer, wherein the intermediate layer comprises a composite material containing a first metal material and a lithium-ion conductor, wherein the first metal material is a first metal, an alloy containing the first metal and lithium, a compound containing the first metal and lithium, or a combination thereof, wherein the first negative active material layer comprises a carbon-containing negative active material and optionally a first negative active material comprising a second metal, a metalloid, or a combination thereof.

[0006] US 2020 / 0395584A1 describes electrochemical cells provided that include a seal impermeable to a liquid electrolyte, connected to a solid lithium-ion-conducting electrolyte, such that a lithium-metal negative electrode is effectively insulated and protected from contact with a liquid electrolyte, a gel electrolyte used as the catholyte in the positive electrode, or both. Some of the electrochemical cells include a series of electrochemical stacks that can be stacked in a variety of configurations, including configurations that share a lithium-metal negative electrode.

[0007] US 2020 / 0303718A1 describes lithium-ion batteries and solid-state lithium-ion batteries, as well as a method for manufacturing such batteries. The solid-state batteries comprise a multilayer structure with at least one layer containing anode materials (“anode layer”), at least one layer containing solid electrolyte materials (“electrolyte layer”), and at least one layer containing cathode materials (“cathode layer”).

[0008] EP 4 310 981 A1 describes a solid-state battery comprising a positive electrode, a negative electrode and a solid electrolyte membrane arranged between the positive electrode and the negative electrode, and further comprising a first composite carbon layer and a second composite carbon layer between the negative electrode and the solid electrolyte membrane.

[0009] US 2023 / 0275258A1 describes a solid composite electrolyte comprising i) at least one polymer; ii) at least one solid, ionically conductive, sulfide-based inorganic particle; and iii) at least one lithium salt, wherein i) is selected from the group consisting of (co)polymers with recurring units, including vinylidene fluoride (VDF), alkylene carbonate, acrylonitrile, silane, fluorosilane, acrylate, caprolactone, and mixtures thereof, and wherein the amount of ii) at least one solid, sulfide-based, ionically conductive inorganic particle is 40.0 to 98.0 wt%, preferably 60.0 to 97.0 wt%, and more preferably 70.0 to 96.0 wt%, based on the total weight of the solid composite electrolyte.The invention also relates to a slurry for producing a solid compound electrolyte, comprising i) at least one polymer, ii) at least one solid, sulfide-based, inorganic particle with ionic conductivity, iii) at least one lithium salt and iv) at least one polar, aprotic solvent, to a solid-state battery comprising the solid compound electrolyte, and to using the solid compound electrolyte in an electrolyte or electrode of a solid-state battery to improve the ionic conductivity and mechanical properties.

[0010] US 2022 / 0045354A1 describes a fully solid secondary battery comprising: a cathode layer with a cathode active material layer; an anode layer;and a solid electrolyte layer between the cathode layer and the anode layer, wherein the solid electrolyte layer comprises a solid electrolyte, wherein the anode layer comprises an anode current collector, a first anode active material layer in contact with the solid electrolyte layer, and a second anode active material layer between the anode current collector and the first anode active material layer, wherein the first anode active material layer is a lithium-containing first metal layer, wherein the second anode active material layer comprises a carbon-containing anode active material or a carbon-containing anode active material and a second metal, and wherein a surface of the solid electrolyte layer adjacent to the first anode active material layer has a porosity of 40 percent or less.

[0011] While current separators fulfill their purpose, the aim of the invention is to provide new and improved anode and separator designs.

[0012] The object of the invention is achieved by means of an anode electrode for a battery cell. The anode electrode comprises an anode current collector with a first surface and an anode-supported electrolyte separator arranged on the first surface. The anode-supported electrolyte separator has at least one electrolyte selected from the following compositions: a) yLi₂S·(100-yx)P₂S₅·xP₂O₅ where y is in the range of 70 mol percent to 80 mol percent and x is in the range of 1 mol percent to 10 mol percent, b) Li 10 MP2S 12 where M is at least one of Si, Ge and Sn, and c) argyrodite, which has the composition: A 12-m-x + (M m+ Y4 2- )Y 2-x 2- X x - where A+ = Li + , Cu + , Ag + ; N m+ = Si 4+ , Ge 4+ , Sn 4+ , P 5+ , As 5+ ; Y 2- = O 2- , S 2- , Se 2- , Te 2- , X - = Cl - , Br - , I - ; and 0 ≤ x ≤ 2. Furthermore, the anode-supported electrolyte separator has a thickness in the range of 1 micrometer to 100 micrometers.

[0013] The anode-supported electrolyte separator has a second surface that defines a second area. This second area is larger than a third area defined by a third surface of an adjacent cathode. The anode electrode further comprises an anode that contacts the first surface. The anode has a fourth surface that defines a fourth area, and the anode-supported electrolyte separator contacts this fourth surface. The area of ​​the anode is the same size as the second area of ​​the anode-supported electrolyte separator, resulting in an overhang and an overlapping area of ​​the anode and the anode-supported electrolyte separator that extends beyond and over the second area and a perimeter of the third surface of the cathode.The overhang is sufficiently wide at every point around the circumference of the cathode to separate the cathode from the anode if the anode and the anode-supported electrolyte separator bend and touch the cathode.

[0014] According to one embodiment, the anode-supported electrolyte separator touches the first surface of the anode current collector.

[0015] According to another embodiment, the anode comprises one or more active anode materials selected from the group consisting of: silicon, silicon-carbon composite, hard carbon, graphite, silicon oxide (SiOx, where x is either 1 or 2) and lithium titanate (LTO).

[0016] According to another embodiment, the anode has silicon with a thickness in the range of 1 micrometer to 50 micrometers.

[0017] According to a further embodiment, the electrolyte is yLi2 S · (100-yx)P2S5 xP2O5, where y is in the range of 70 mol percent to 80 mol percent and x is in the range of 1 mol percent to 10 mol percent, and the electrolyte is present in the range of 50 weight percent to 99 weight percent of the total weight of the anode-supported electrolyte separator, and the anode-supported electrolyte separator also has an electrolyte binder that is present in the range of 1 weight percent to 50 weight percent of the total weight of the anode-supported electrolyte separator.

[0018] According to another embodiment, the electrolyte binder comprises one or more binders selected from the group consisting of: styrene butadiene rubber (SBR), hydrogenated nitrile butadiene rubber (HNBR), polyvinylidene fluoride (PVDF), poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP), polytetrafluoroethylene (PTFE) and poly(tetrafluoroethylene-co-perfluoro(3-oxa-4-pentenesulfonic acid)) lithium salt.

[0019] According to a further embodiment, the anode-supported electrolyte separator also comprises one or more liquid electrolyte diluents selected from the group consisting of: 1,1,2,2-tetrafluoroethylene-2,2,3,3-tetrafluoropropyl ether (TTE), bis(2,2,2-trifluoroethyl) ether (BTFE), tris(2,2,2-trifluoroethyl) orthoformate (TFEO), fluorobenzene (FB), 1,2-difluorobenzene (DFB), bis(2,2-difluoroethyl) ether (BDE), 1,1,2,2-tetrafluoroethyl ether (ETE), hexafluoroisopropyl methyl ether (HFME), 1,1,2,2-tetrafluoroethyl-2,2,2-trifluoroethyl ether, 1,1,2,3,3,3-hexafluoropropyl ether, nonafluorobutyl methyl ether (isomer mixture). Difluoromethyl-2,2,3,3-tetrafluoropropyl ether, 1H,1H,5H-octafluoropentyl-1,1,2,2-tetrafluoroethyl ether (OTE), 1,1,2,3,3,3-hexafluoropropyl-2,2,2-trifluoroethyl ether, 1,1,1,2,2,3,4,5,5,5-decafluoro-3-methoxy-4-(trifluoromethyl)pentane, fluoromethyl-1,1,1,3,3,3-hexafluoroisopropyl ether, 1,1,2,3,3,3-hexafluoroisopropyl methyl ether, hexafluoroisopropyl methyl ether, methyl 2,2,3,3,3-pentafluoropropyl ether and methyl 1,1,2,2-tetrafluoroethyl ether.

[0020] According to a further embodiment, the anode-supported electrolyte separator also comprises one or more ionic liquids at room temperature selected from the group consisting of: 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (EMIM-TFSI), 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (BMIM-TFSI), N-propyl-N-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide (PYR13TFSI), 1-butyl-1-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide (PYR14TFSI), 1-ethyl-3-methylimidazolium bis(fluorosulfonyl)imide (EMIM-FSI), 1-butyl-3-methylimidazolium bis(fluorosulfonyl)imide (BMIM-FSI), N-propyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide (PYR13-FSI) and 1-butyl-1-methylpyrrolidinium bis(fluorosulfonyl)imide (PYR14-FSI).

[0021] According to a further embodiment, the anode-supported electrolyte separator comprises one or more solvated ionic liquid electrolytes selected from the group consisting of: lithium triglyme bis(trifluoromethanesulfonyl)imide (Li[G3]TFSI), lithium tetraglyme bis(trifluoromethanesulfonyl)imide (Li[G4]TFSI), lithium triglyme bis(fluorosulfonyl)imide (Li[G3]FSI), lithium tetraglyme-bis(fluorosulfonyl)imide (Li[G4]FSI), lithium triglyme bis(pentafluoroethenesulfonyl)imide (Li[G3]BETI), lithium tetraglyme bis(pentafluoroethenesulfonyl)imide (Li[G4]BETI), cyclic lithium triglyme TFSI derivative 1,2,3-dithiazolidine-4,4,5,5-tetrafluoro-1,1,3,3-tetraoxide (Li[G3]CTFSI), cyclic Lithium tetraglyme TFSI derivative 1,2,3-dithiazolidine-4,4,5,5-tetrafluoro-1,1,3,3-tetraoxide (Li[G4]CTFSI), lithium triglyme perchlorate (Li[G3]ClO4), lithium tetraglyme perchlorate (Li[G4]ClO4), lithium triglyme tetrafluoroborate (Li[G3]BF4) and lithium tetraglyme tetrafluoroborate (Li[G4]BF4).

[0022] According to another embodiment, the battery cell also has an anode comprising silicon and a fourth surface defining a fourth area, wherein the anode touches the first surface of the anode current collector and the anode-supported electrolyte separator touches the fourth surface of the anode.

[0023] According to another embodiment, the overhang is in the range of 1 millimeter to 2 millimeters.

[0024] According to another embodiment, the anode current collector is a bipolar current collector.

[0025] According to another embodiment, the battery cell also has a cathode current collector, and the cathode touches the cathode current collector.

[0026] According to another embodiment, the cathode comprises an active cathode material, a cathode electrolyte, and a cathode binder. The active cathode material is present in the range of 64% to 98.5% by weight of the total weight of the cathode, the cathode binder is present in the range of 1% to 9% by weight of the total weight of the cathode, and the cathode electrolyte is present in the range of 10% to 17% by weight of the total weight of the cathode.Furthermore, the active cathode material comprises one or more active cathode materials selected from the following: lithium iron phosphate (LFP), sulfur (S), iron sulfide (FeS2), and lithium sulfide (Li2S); the cathode binder comprises one or more cathode binders selected from the group consisting of styrene butadiene rubber (SBR), hydrogenated nitrile butadiene rubber (HNBR), polyvinylidene fluoride (PVDF), poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP), polytetrafluoroethylene (PTFE), poly(ethylene oxide) (PEO), and poly(tetrafluoroethylene-co-perfluoro(3-oxa-4-pentenesulfonic acid)) lithium salt; and the cathode electrolyte is Li2. S·(100-yx)P2S5 xP2O5 contains, where y is in the range of 70 mol percent to 80 mol percent and x is in the range of 1 mol percent to 10 mol percent.

[0027] A method for forming an anode-supported electrolyte separator is also described. This method serves to illustrate the structural design of the anode electrode according to the invention and its embodiments, as it incorporates the features of the anode electrode in its process steps. The method comprises forming a slurry of an electrolyte and an electrolyte binder in a binder-solvent, applying the slurry to a) a first surface of an anode current collector or b) a second surface of an anode, drying the slurry to form an anode-supported electrolyte separator, and calendering the anode-supported electrolyte separator. The at least one electrolyte has a composition selected from the group consisting of: a) yLi2S·(100-yx)P2S5·xP2O5, where y is in the range of 70 mol percent to 80 mol percent and x is in the range of 1 mol percent to 10 mol percent, b) Li 10MP2S 12 , where M is at least one of Si, Ge and Sn, and c) argyrodite having the following composition: A 12-m-x + (M m+ Y4 2- )Y 2-x 2- X x - where A + = Li + , Cu + , Ag + ; NP m+ = Si 4+ , Ge 4+ , Sn 4+ , P 5+ , As 5+ ; Y 2- = O 2- , S 2- , Se 2- , Te 2- , X - = Cl - , Br - , I - ; and 0 ≤ x ≤ 2. Furthermore, the anode-supported electrolyte separator has a thickness in the range of 1 micrometer to 100 micrometers.

[0028] The drawings described here serve for illustrative purposes. Fig. Figure 1 shows a vehicle and a powertrain with a secondary battery. Fig. 2A indicates a battery. Fig. 2B shows a pouch or prismatic battery cell. Fig. 2C shows a cylindrical battery cell. Fig. 2D shows a button cell battery. Fig. Figure 3A shows the building blocks for a bipolar battery cell according to the present description. Fig. Figure 3B shows the structure of a bipolar battery cell. Fig. Figure 4A shows a side view of a battery cell stack. Fig. 4B a front view of a battery cell stack. Fig. Figure 5 illustrates a method for forming an anode-supported solid electrolyte or semi-solid electrolyte. Fig. Figure 6 illustrates a method for coating an anode with a solid electrolyte or a semi-solid electrolyte. Fig. Figure 7 shows a side view of a conventional battery cell stack with a self-supporting polymer separator. Fig. Figure 8 shows a side view of a cathode-supported solid electrolyte separator. Fig. Figure 9 illustrates the capacity change (milliampere-hours) of a conventional battery cell over 80 cycles using a polymer separator, with the capacity on the y-axis and the number of cycles on the x-axis. Fig. Figure 10 shows the capacity change (milliampere-hours) of a battery cell with an anode-supported solid electrolyte separator over 80 cycles, with the capacity on the y-axis and the number of cycles on the x-axis.

[0029] Furthermore, there is no intention to be bound by any express or implied theory set forth in the preceding introduction, summary, or detailed description. It should be understood that in the drawings, corresponding reference numbers point to identical or equivalent parts and features.

[0030] The following section provides detailed references to several examples of the description, which are illustrated in the accompanying drawings. Wherever possible, the same or similar reference numbers are used in the drawings and the description to indicate identical or similar parts or steps. The drawings are simplified and not to scale.

[0031] This description relates to anode-supported electrolyte separators and a method for forming anode-supported electrolyte separators. In various applications, the anodes are integrated with the supported electrolyte separator into battery cells and secondary batteries, such as prismatic, pouch-shaped, cylindrical, or coin-shaped battery cells. The batteries can then be used in electric or hybrid electric vehicles.

[0032] The term "vehicle" as used here is not limited to motor vehicles. While the technology presented here is primarily described in the context of electric and hybrid electric vehicles, it is not limited to these. The concepts can be used in a wide variety of applications, for example, in conjunction with components used in motorcycles, mopeds, locomotives, aircraft, watercraft, and other vehicles, as well as in other applications that use batteries, such as...in consumer electronics, in building power supply systems and in portable power plants used to supply electricity to remote construction sites, emergency power supplies and continuous power supplies for buildings and equipment, which can be powered, for example, by solar or wind generators, power grids and fuel-based generators such as gasoline, propane, kerosene or diesel generators, as well as Sterling engines.

[0033] Fig. Figure 1 illustrates a vehicle 100 having a drive system 120. The drive system 120 generally includes an electric motor 124 and a secondary battery 126 for supplying power to the electric motor 124. In many embodiments of the drive system 120, the drive system 120 also includes an inverter 128 for converting direct current (DC), as supplied by the battery 126, into alternating current (AC), as used by the electric motor 124. The inverter 128 can be contained in a power electronics module 130, which includes, for example, transistors and diodes for switching the current from DC to AC and vice versa.

[0034] A control unit 132 is connected to and programmed with the inverter 128 to control and manage the operation of the electric motor 124 and the associated hardware, including the inverter 128. The electric motor 124 is connected to a gearbox (drive unit) 136 and a drivetrain 138, which transmits mechanical power and rotation to the wheels 140 of the vehicle 100. The control unit 132 has one or more processors and tangible, non-transferable memory 134. A fuel-powered engine may also be included in the drive system of hybrid electric vehicles.

[0035] To return to the electric motor 124, the electric motor 124 is powered by the battery 126 and has a stator 142 and a rotor 144 arranged with the stator 142. The stator 142 is the stationary part of the electric motor 124. The stator 142 provides a rotating magnetic field with which the stationary magnetic field of the rotor 144 attempts to align, causing the rotor 144 to rotate, which can be described as "motor operation." In other applications, the rotating field of the rotor 144 (as caused by the physical rotation) generates an electric current in the stator 142—this mode of operation is called "generation mode," and the electric motor 124 used in this way is called a generator. In applications in traction vehicles, motor operation provides the movement of the vehicle 100.In generation mode, some of the energy recovered by braking when the vehicle comes to a stop is stored back in the vehicle battery 126.

[0036] It will be directed to the Fig. 2A, Fig. 2B, Fig. 2C, Fig. 2D, Fig. 3A and Fig. 3B referred to the examples of secondary batteries 126 for supplying power to an electric vehicle 100, as in Fig. Figure 1 shows an electric vehicle 100. As mentioned above, the secondary batteries 126 are to be understood as rechargeable batteries that can be discharged when a load is applied and recharged when an external power source is applied. In the Fig. 2A, Fig. 2B, Fig. 2C and Fig. In Figure 2D, the battery 126 is shown connected to a load 148, such as the electric motor 124. Other loads 148 also include various systems in the vehicle 100, such as climate control and infotainment systems. The battery 126 has one or more battery cells 150 that are joined together. The battery cells 150 can be, for example, bag-shaped, prismatic, cylindrical, or button cell-like, as described below. With reference to the Fig. 2B, Fig. 2C and Fig. During discharge, when a load 148 is applied to the battery 126, Li+ ions move from the anode 158 to the cathode 156 through the separator 160, which also provides the electrolyte 162. Equivalent electrons e- move through the circuit 146 from the cathode 156 to the anode 158 and provide voltage to the load 148. During charging, when an external voltage is applied, Li+ ions move from the cathode 156 to the anode 158 through the anode-supported electrolyte separator 160 and can be stored in the anode 158.

[0037] Each battery cell contains 150 cells, as used in the Fig. 2B, Fig. 2C and Fig. The 2D representation generally includes a cathode current collector 152, a cathode 156 arranged on the cathode current collector 152, an anode current collector 154, an anode 158 arranged on the anode current collector 154, and an anode-supported electrolyte separator 160 located between the cathode 156 and the anode 158. While unipolar solid-state battery cell arrangements are shown below in Fig. Figures 2B to 2D show battery cells 150 with a cathode current collector 152, a cathode 156, an anode current collector 154, an anode 158, and a solid-state electrolyte separator 160. It should be noted that alternative arrangements are also possible, such as battery cells 150 with cathodes 156 arranged on both sides of the cathode current collector 152, anodes 158 arranged on both sides of the anode current collector 154, arrangements with multiple stacks of cathode current collectors 152, cathodes 156, anode current collectors 154, anodes 158, and anode-supported electrolyte separators 160, as well as arrangements with bipolar battery cell designs. Fig. 3A and Fig. 3B are described.

[0038] In embodiments, the battery cell 150 is of Fig. 2B is configured as a pouch-type battery cell or as a prismatic battery cell. In both configurations, which have multiple cathodes 156 and multiple anodes 158, anode-supported electrolyte separators 160 are provided between the cathodes 156 and the anodes 158. In a pouch-type cell, the tabs 164 are welded to the cathode current collectors 152 and the anode current collectors 154, and the cover 166 is in the form of a flexible foil pouch made of aluminum or another material. In contrast, prismatic cells have terminals connecting the cathode current collectors 152 and the anode current collectors 154, and the cover 166 is formed from a relatively rigid housing, typically in the form of a cuboid. The tabs 164 or terminals, which are connected to the cathode current collectors 152 of several battery cells 150, are connected to each other, for example by a busbar 168 (see Fig. 2A) or another electrical connection, and the tabs 164 or terminals connected to the anode current collectors 154 of several battery cells 150 are connected to each other, for example by a busbar 169 (see Fig. 2A) or another electrical connection.

[0039] Alternatively, the battery cell can be 150 from Fig. 2C can also be configured as a cylindrical battery cell 150. In this configuration, the cathode current collector 152, the anode current collector 154, the cathode 156, the anode 158, and one or more anode-supported electrolyte separators 160 are in the form of long strips rolled into a cylinder or a gel-like roll. As with the prismatic cell, the cover 166 is formed from a relatively rigid housing made of aluminum or another material. Tabs 164 are welded to the cathode current collector 152 and the anode current collector 154. The tabs 164, which are connected to the cathode current collectors 152 of several battery cells 150, are connected to each other, for example, by a busbar 168 (see Fig. 2A) or another electrical connection, and the tabs 164 or terminals connected to the anode current collectors 154 of several battery cells 150 are connected to each other, for example by a busbar 169 (see Fig. 2A) or another electrical connection.

[0040] In other alternative embodiments, the battery cell 150 is packaged in a button cell, as in Fig. The design is shown in 2D. In this embodiment, the cathode current collector 152, the anode current collector 154, the cathode 156, the anode 158, and the anode-supported electrolyte separators 160 are in the form of discs, sandwiched together within the coin packaging, which forms the cover 166 and includes a cap 170 and a can 172. A spring washer 174 can be inserted between the cathode current collector 152 and the cap 170.

[0041] Bipolar battery cell designs feature battery cells 150 connected in series. The battery cells 150 have one or more current collectors that are bipolar. Each current collector has a cathode 156 applied to one side of the current collector and an anode 158 applied to the other side of the current collector. The use of bipolar designs further increases the energy density because the packaging for individual battery cells can be eliminated and the number of connections between the battery cells can be reduced, as the current flows through the entire battery stack. Fig. Figure 3A shows embodiments of the building blocks 300, 302, and 304 for forming bipolar battery cells. The building block 300 has a cathode 156, which is applied to a first side 306 of a bipolar current collector 308, an anode 158, which is applied to a second side 310 of the bipolar current collector 308, and an anode-supported electrolyte separator 160, which is applied to a surface 312 of the anode 158 that faces the bipolar current collector 308. The component 302 has a cathode 156 which is applied to a first side 306 of a bipolar current collector 308, and the component 304 has an anode 158 which is applied to a second side 310 of the bipolar current collector 308, and an anode-supported electrolyte separator 160 which is applied to a surface 312 of the anode 158 which is opposite the current collector 308.The building blocks 300, 302, 304 are arranged to form a stack of cathodes 156 and anodes 158 and have anode-supported electrolyte separators 160 between the cathodes 156 and anodes 158 and bipolar current collectors 308 between each stack of a cathode 156, an anode-supported electrolyte separator 160 and an anode 158, as in the embodiment of . Fig. 3B is shown. Several bipolar battery cells can be packed in a single cover 166, which is shown above with reference to the Fig. 2A, Fig. 2B, Fig. 2C and Fig. The packaging is similar to the one described in 2D. The bipolar collector 308 provides both the anode current collector 154 and the cathode current collector 152, which are located in the Fig. 2A to 2D, 4A and 4B are shown.

[0042] In the various types of battery cells 150 mentioned above, and with further reference to the Fig. 4A and Fig. In 4B, the anode-supported electrolyte separator 160 is supported on and in contact with a surface 403 of the anode 158, while the surface 405 of the anode 158 contacts a surface 407 of the anode current collector 154. Alternatively, the anode-supported electrolyte separator 160 contacts the surface of the anode current collector 154, as further described here. In both embodiments, the anode-supported electrolyte separator 160 is arranged on the surface 407 of the anode current collector 154. In some embodiments, the anode-supported electrolyte separator 160 covers the entire surface 403 of the anode 158. Furthermore, the area 402, 406 of the surface 403 of the anode 158 or of the anode-supported electrolyte separator 160 is selected to be larger than, and is also larger than, the area 404 of the cathode 156 to which the anode-supported electrolyte separator 160 abuts.Furthermore, the area 402 of the anode 158 has the same size as the area 406 of the anode-supported electrolyte separator 160. This creates an overhang 408, i.e., an overlapping area 413 of the anode 158 and the anode-supported electrolyte separator 160, which overlaps and extends beyond the area 404 and the perimeter 411 of a surface 417 of the cathode 156. The width 409 of the overhang 408 is between 1 millimeter and 2 millimeters, including all values ​​and ranges therein. In embodiments, the width 409 of the overhang 408 is uniform over the entire perimeter 411 of the cathode 156. Alternatively, the width 409 of the overhang 408 varies around the perimeter 411 of the cathode 156.It should be noted, however, that the overhang at any point on the circumference 411 of the cathode 156 is sufficiently wide to separate the cathode 156 from the anode 158 should the anode 158 and the anode-supported electrolyte separator 160 bend and touch the cathode 156. The presence of the anode-supported electrolyte separator 160 on the overhang 408 prevents electrical short circuits from occurring if the overhang 408 bends and touches the cathode 156, since the separator 160, and not the anode 158, touches the cathode 156. The surfaces 402, 404, 406 are defined in a direction that is generally orthogonal to the thickness 410 of the stack, and the surfaces 403, 405, 417 are generally perpendicular.

[0043] As from the Fig. As shown in Figures 2A to 4B, the cathode current collector 152, the anode current collector 154, and the bipolar current collector 308 are made of conductive materials. In some embodiments, the cathode current collector 152 is made of aluminum. Alternatively or additionally, the cathode current collector 152 can also have copper-clad aluminum and stainless steel. The anode current collector 154 has copper in some cases. Alternatively or additionally, the anode current collector can have one or more of the elements nickel, stainless steel, and titanium. The bipolar current collector 308 has one or more of the following materials: aluminum, copper-clad aluminum, stainless steel, copper, nickel, and titanium. The current collectors 152, 154, and 308 are shown in the form of a foil; however, it should be noted that other forms, such as a mesh, can also be used. In certain embodiments, the foil current collectors are gas-impermeable.The cathode current collector 152 has a thickness 412 in the range of 5 micrometers to 50 micrometers, including all values ​​and ranges therein, e.g., in the range of 5 micrometers to 25 micrometers. The anode current collector 154 has a thickness 414 in the range of 4 micrometers to 50 micrometers, including all values ​​and ranges therein, e.g., in the range of 4 micrometers to 25 micrometers. A bipolar current collector 308 has a thickness in the range of 5 micrometers to 50 micrometers, including all values ​​and ranges therein. In certain embodiments, one or both current collectors have a roughened surface, thereby increasing the surface area of ​​the current collector.

[0044] The cathode 156 has a source of lithium ions (Li). +The cathode can reversibly deposit or intercalate lithium ions, which determines, for example, the capacity and average voltage of a battery. In embodiments, the cathode comprises an active cathode material, a binder, optionally a cathode electrolyte, and optionally a conductive filler. The active cathode material comprises one or more of the following active cathode materials: lithium iron phosphate (LFP), sulfur (S), iron sulfide (FeS₂), and lithium sulfide (Li₂S). In embodiments, the active cathode material also comprises carbon black, wherein the carbon black is present in the range of 0.1% to 40% by weight of the total weight of the active cathode material, including all values ​​and ranges therein, with the total weight percentage being 100% and the remaining weight percentage comprising the aforementioned active cathode materials.The binder comprises one or more of the following cathode binders: styrene-butadiene rubber (SBR), hydrogenated nitrile butadiene rubber (HNBR), polyvinylidene fluoride (PVDF), poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP), polytetrafluoroethylene (PTFE), poly(ethylene oxide) (PEO), and poly(tetrafluoroethylene-co-perfluoro(3-oxa-4-pentenesulfonic acid)) lithium salt. The cathode electrolyte contains yLi₂S·(100-yx)P₂S₅·xP₂O₅, where y is in the range of 70 mol percent to 80 mol percent, including all values ​​and ranges therein, and x is in the range of 1 mol percent to 10 mol percent, including all values ​​and ranges therein (LPSO). The conductive filler comprises one or more metal wires, metal oxides, carbon nanotubes, carbon black, graphite flakes, graphite nanoparticles, graphite nanoplatelets and combinations thereof.In embodiments, the active cathode material is present in the range of 64% to 98.5% by weight of the total weight of the cathode, including all values ​​and ranges therein; the cathode binder is present in the range of 1% to 9% by weight of the total weight of the cathode, including all values ​​and ranges therein; optionally, a cathode electrolyte is present in the range of 10% to 17% by weight of the total weight of the cathode, including all values ​​and ranges therein; and optionally, a conductive filler is present in the range of 0.5% to 25% by weight of the total weight of the cathode, including all values ​​and ranges therein, wherein the total weight of the cathode is 100%.In embodiments, the active cathode material, the cathode binder, and the conductive filler are applied to the cathode 156 in a slurry that is applied to the cathode current collector 152. The slurry is formed with a liquid such as toluene, anisole, N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAc), dimethylformamide (DMF), or acetonitrile (MeCN).

[0045] The cathode 156 has a thickness 416 in the range of 80 micrometers to 500 micrometers, including all values ​​and ranges within this range, for example, 110 micrometers. The cathode electrode 157, which comprises both the cathode current collector 152 and the cathode 156, has a thickness 418 in the range of 85 micrometers to 550 micrometers, including all values ​​and ranges within this range, when the cathode material is formed on one side of the cathode current collector 152. When the cathode material is formed on both sides of the cathode current collector 152, the cathode electrode 157 has a thickness in the range of 165 micrometers to 1050 micrometers, including all values ​​and ranges within this range for a double-sided cathode electrode 157, such as in the range of 205 micrometers to 500 micrometers.

[0046] The anode 158 comprises active anode materials capable of reversible incorporation or intercalation of lithium ions at a lower electrochemical potential than the cathode material 156, resulting in an electrochemical potential difference between the anode 158 and the cathode 156. The active anode material comprises one or more of the following materials: silicon, silicon-carbon composite, hard carbon (non-graphitizing carbon), graphite, silicon dioxide (SiOx, where x is either 1 or 2), and lithium titanate (LTO).

[0047] In certain embodiments, the anode is formed by vapor deposition of the active anode material onto the anode current collector 154, either by physical or chemical vapor deposition. Alternatively, the anode can be formed by applying a coating to the anode current collector 154 using a deposition process, such as a slurry-based process, a hot rolling process, extrusion, or additive manufacturing. In embodiments, the anode 158 has a thickness 420 in the range of 10 micrometers to 150 micrometers, including all values ​​and ranges therein. In preferred embodiments, the anode is silicon deposited by physical vapor deposition and has a thickness in the range of 1 micrometer to 100 micrometers, including all values ​​and ranges therein, e.g., 14 micrometers to 15 micrometers.The combined anode 158 and the anode current collector 154 form an anode electrode 159, which has a thickness 422 in the range of 1 micrometer to 200 micrometers, including all values ​​and ranges.

[0048] In alternative embodiments, the anode 158 is initially omitted and forms in situ on the anode current collector 154 during the first charging cycle through the deposition of lithium metal. In such embodiments, the anode-supported electrolyte separator 160 is arranged on the anode current collector 154 and contacts it before the first charging cycle. Such an embodiment is referred to as "anode-free".

[0049] As mentioned previously, the anode-supported electrolyte separator 160 is embedded or at least partially enclosed between the cathode 156 and the anode 158 to prevent the cathode 156 from touching the anode 158. The anode-supported electrolyte separator 160 comprises an electrolyte that provides a medium between the cathode 156 and the anode 158 through which lithium ions migrate, but which electrically insulates the cathode 156 from the anode 158 and prevents a short circuit. The anode-supported electrolyte separator 160 is at least a solid electrolyte or a semi-solid electrolyte.

[0050] A solid-state electrolyte is an electrolyte that has a solid state of matter. The anode-supported solid-state electrolyte separator 160 has a sulfide solid-state electrolyte, such as a lithium-phosphorus-sulfur electrolyte (LPS) or a lithium-phosphorus-sulfur-oxygen electrolyte (LPSO). In embodiments, the anode-supported solid-state electrolyte separator 160 has one or more of the following electrolyte compositions: yLi₂S·(100-yx)P₂S₅·xP₂O₅, where y is in the range of 70 mol percent to 80 mol percent, including all values ​​and ranges therein, and x is in the range of 1 mol percent to 10 mol percent, including all values ​​and ranges therein (LPSO). 10 MP2S 12 where M is at least one of Si, Ge and Sn (LPS), and argyrodite with the formula: A 12-m-x + (M m+ Y4 2- )Y 2-x 2- X x - where A + = Li+ , Cu + , Ag + ; NP m+ = Si 4+ , Ge 4+ , Sn 4+ , P 5+ , As 5+ ; Y 2- = O 2- , S 2- , Se 2- , Te 2- ; and X - = Cl - , Br - , I -; 0 ≤ x ≤ 2, such as Li6PS5Cl. The electrolyte composition ranges from 50% to 99% by weight of the total weight of the anode-supported solid electrolyte separator 160, including all values ​​and ranges contained therein. Furthermore, the anode-supported solid electrolyte separator 160 has an electrolyte binder present in the range of 1% to 50% by weight of the total weight of the solid electrolyte separator, including all values ​​and ranges contained therein. The electrolyte binder comprises one or more of the following binders: styrene-butadiene rubber (SBR), hydrogenated nitrile butadiene rubber (HNBR), polyvinylidene fluoride (PVDF), poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP), polytetrafluoroethylene (PTFE), poly(tetrafluoroethylene-co-perfluoro(3-oxa-4-pentenesulfonic acid)) lithium salt and combinations thereof.In some embodiments, the solid electrolyte and the electrolyte binder are deposited on the anode 158 in a slurry of the electrolyte mixed with the binder in a solution of the binder and a binder solvent. The binder solvent is selected from one or more of the following solvents: toluene, alkane, anisole, and organophosphate. In certain embodiments, the solid electrolyte is present in the slurry in the range of 28 to 60 percent by weight of the total weight of the slurry, including all values ​​and increases therein. The electrolyte binder is present in the solution in the range of 0.4 percent by weight to 18 percent by weight of the total weight of the solution, including all values ​​and ranges therein.The anode-supported solid-state electrolyte separator 160 has a thickness 424 in the range of 1 micrometer to 100 micrometers, including all values ​​and areas within this range. Furthermore, the anode-supported solid-state electrolyte separator 160 has a porosity in the range of 1 percent to 50 percent of the total volume, which is generally defined by the perimeter of the anode-supported solid-state electrolyte separator 160, including all values ​​and areas within this range.

[0051] In further or alternative embodiments, the anode-supported electrolyte separator 160 comprises a semi-solid electrolyte. Here, a semi-solid electrolyte is understood to be a solid matrix comprising the anode-supported solid electrolyte separator, which is permeated in the spaces between the solid matrix spaces with a liquid electrolyte and is described in some cases as a gel. In some cases, the semi-solid electrolyte is referred to as a gel. In some embodiments, the semi-solid electrolyte comprises a solvated ionic liquid electrolyte.The solvated ionic liquid electrolytes contain one or more of the following solvated ionic liquid electrolytes: lithium triglyme bis(trifluoromethanesulfonyl)imide (Li[G3]TFSI), lithium tetraglyme bis(trifluoromethanesulfonyl)imide (Li[G4]TFSI), lithium triglyme bis(fluorosulfonyl)imide (Li[G3]FSI), lithium tetraglyme bis(fluorosulfonyl)imide (Li[G4]FSI), lithium triglyme bis(pentafluoroethenesulfonyl)imide (Li[G3]BETI), lithium tetraglyme bis(pentafluoroethenesulfonyl)imide (Li[G4]BETI), cyclic lithium triglyme TFSI derivative 1,2,3-dithiazolidine-4,4,5,5-tetrafluoro-1,1,3,3-tetraoxide (Li[G3]CTFSI), cyclic lithium tetraglyme TFSI derivative 1,2,3-dithiazolidine-4,4,5,5-tetrafluoro-1,1,3,3-tetraoxide (Li[G4]CTFSI), lithium triglyme perchlorate (Li[G3]ClO4), lithium tetraglyme perchlorate (Li[G4]ClO4), lithium triglyme tetrafluoroborate (Li[G3]BF4) and Lithium tetraglyme tetrafluoroborate (Li[G4]BF4).The semi-solid electrolyte is formed by applying the solvated ionic liquid electrolyte to the anode-supported solid electrolyte separator. The solvated ionic liquid electrolyte infiltrates the interstices of the solid matrix, a process that can be aided by applying a vacuum. The solvated ionic liquid electrolyte can be applied before the anode-supported electrolyte separator is installed in the battery cell, or the anode-supported electrolyte separator can be installed in the battery cell. If applied prior to assembly, any excess solvated liquid electrolyte is removed before assembly. The anode-supported semi-solid electrolyte separator 160 has a thickness ranging from 1 micrometer to 100 micrometers, including all values ​​and ranges within this range.

[0052] In optional embodiments, the anode-supported electrolyte separator 160, which comprises one or more solvated liquid electrolytes, also includes at least one liquid electrolyte diluent and an ionic liquid at room temperature. The liquid electrolyte diluents include fluorinated ether electrolytes.Fluorinated ether electrolytes contain one or more of the following substances: 1,1,2,2-tetrafluoroethylene, 2,2,3,3-tetrafluoropropyl ether (TTE), bis(2,2,2-trifluoroethyl) ether (BTFE), tris(2,2,2-trifluoroethyl) orthoformate (TFEO), fluorobenzene (FB) and 1,2-difluorobenzene (DFB), bis(2,2-difluoroethyl) ether (BDE), 1,1,2,2-tetrafluoroethyl ether (ETE), hexafluoroisopropyl methyl ether (HFME), 1,1,2,2-tetrafluoroethyl-2,2,2-trifluoroethyl ether, 1,1,2,3,3,3-hexafluoropropyl ether, non-fluorobutyl methyl ether (isomer mixture), difluoromethyl-2,2,3,3-tetrafluoropropyl ether. 1H,1H,5H-octafluoropentyl-1,1,2,2-tetrafluoroethyl ether (OTE), 1,1,2,3,3,3-hexafluoropropyl-2,2,2-trifluoroethyl ether, 1,1,1,2,2,3,4,5,5,5-decafluoro-3-methoxy-4-(trifluoromethyl)pentane, Fluoromethyl 1,1,1,3,3,3-hexafluoroisopropyl ether, 1,1,2,3,3,3-hexafluoroisopropyl methyl ether, hexafluoroisopropyl methyl ether, methyl 2,2,3,3,3-pentafluoropropyl ether and methyl 1,1,2,2-tetrafluoroethyl ether.The liquid electrolyte diluents and the solvated ionic liquid electrolyte contribute to improving the contact between the solid electrolyte separators and the cathode and anode by filling the gaps created by the deposition process of the cathode 156 and the anode 158 on the cathode current collector 152 and the anode current collector 154, respectively. Room temperature ionic liquids are ionic systems that are in a liquid state at room temperature.Examples of ionic liquids at room temperature include one or more of the following substances: 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (EMIM-TFSI), 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (BMIM-TFSI), N-propyl-N-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide (PYR13TFSI), 1-butyl-1-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide (PYR14TFSI), 1-ethyl-3-methylimidazolium bis(fluorosulfonyl)imide (EMIM-FSI), 1-butyl-3-methylimidazolium bis(fluorosulfonyl)imide (BMIM-FSI), N-propyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide (PYR13-FSI) and 1-Butyl-1-methylpyrrolidiniumbis(fluorosulfonyl)imide (PYR14-FSI).In embodiments, the ratio of at least one of the liquid electrolytes and the ionic liquids at room temperature to at least one of the solid electrolytes and the semi-solid electrolytes is in the range of 1 part by volume to 1 part by volume up to 5 parts by volume to 1 part by volume, including all values ​​and ranges contained therein.

[0053] In Fig. 5 is referred to in the Fig. Sections 2A to 4B describe an embodiment of a method for forming an anode-supported electrolyte. Method 500 comprises, in section 502, the mixing of one or more electrolytes, one or more electrolyte binders, and one or more binder solvents to form a slurry. In embodiments, the slurry is mixed for a period of 10 to 30 minutes, including all values ​​and ranges therein, at a temperature in the range of 21 to 25 degrees Celsius, including all values ​​and ranges therein. In section 504, the slurry is applied to the anode and dried. In certain embodiments, drying is carried out at a temperature in the range of 60 to 150 degrees Celsius, including all values ​​and ranges therein, e.g.,at 80 degrees Celsius for a period ranging from 1 hour to 48 hours, including all values ​​and ranges within that period. Fig. Figure 6 shows the coating 602 applied to the anode 154. Back to Fig. 5: In block 506, the coating 602 is calendered at a pressure exceeding 100 megapascals, for example, in the range of 100 to 600 megapascals, including all values ​​and ranges within that range. In block 508, at least one of the solvated ionic liquid electrolytes, liquid electrolyte diluents, and ionic liquids at room temperature is applied to the anode electrolyte separator 160. The liquid can penetrate the anode electrolyte separator 160, which can be assisted by vacuum, and excess liquid is removed. In block 510, the anode electrode, comprising the anode-supported electrolyte separator 160, is installed in a battery cell 150.As an alternative to the optional block 508, at least one of the solvated ionic liquid electrolytes, liquid electrolyte diluents and ionic liquids is optionally added to the battery cell 150 in block 512 at room temperature after the battery cell 150 has been assembled and sealed. Comparative example

[0054] Three 2032 coin cells were formed using a conventional polymer separator, a cathode-supported solid-state electrolyte separator, and an anode-supported solid-state electrolyte separator. All three battery cells, 700, 800, and 400, which were used in the Fig. 7, Fig. Figures 8 and 4, respectively, featured an aluminum cathode current collector 152, a copper anode current collector 154, and a silicon anode 158 with an energy density of 4.4 milliampere-hours per square centimeter. The cathode 156 for all three battery cells comprised 6 parts by weight of Li₂S and carbon black (including Li₂S at 70% by weight of the active cathode material and carbon black at 30% by weight of the total weight of the active cathode material), 2.5 parts by weight of LPSO₄ 70Li₂S₂5P₂S₅5P₂O₅, 1 part by weight of carbon black, and 0.5 parts by weight of hydrogenated nitrile butadiene rubber. The cathode was applied with a charge of 2 to 3 milligrams per square centimeter.

[0055] Fig. Figure 7 shows a conventional battery cell 700 with a conventional polymer separator 760 formed from an ENTEK silicate separator made of ultra-high molecular weight polyethylene (UHMWPE). Fig. Figure 8 shows a battery cell 800 with a cathode-supported solid-state electrolyte separator. The cathode-supported solid-state electrolyte separator 860 comprises LPSO 70Li2S 25P2S5 5P2O5 and was applied to the cathode as a 25-micrometer film. The in Fig. 4A illustrated anode-supported solid-state electrolyte separator 160 contained LPSO applied to the anode as a 25-micrometer film.

[0056] Fig. Figure 9 shows the decrease in the charging (line A) and discharging capacity (line B) (milli-ampere-hours) (shown on the y-axis) of the conventional 700 battery cell over 80 cycles (shown on the x-axis) at a charging rate of C / 10 (10 hours charging) and a discharging rate of C / 10 (10 hours discharging). Fig.Figure 10 shows the capacity drop (milliampere-hours) during charging (line A) and discharging (line B) (shown on the y-axis) of battery cell 400 with the anode-supported solid electrolyte separator 160 over 80 cycles (shown on the x-axis) at a charging rate of C / 10 and a discharging rate of C / 10. As shown, the capacity of both battery cells did not decrease significantly over the 80 cycles. In the battery cell with the cathode-supported solid electrolyte, an edge short occurred, which prevented the measurement of the capacity as a function of the charge / discharge cycle.

[0057] The electrolytes, battery cells, secondary batteries, and manufacturing processes described here offer a number of advantages. These advantages include, for example, the prevention of short circuits in the battery cell caused by contact between the anode and cathode. They also include the provision of an anode material that is mechanically robust enough for the calendering process used in the deposition of the anode-supported electrolyte separator. Furthermore, they allow for a reduction in separator thickness to increase the cell's energy density. Finally, the technology can be used for both unipolar and bipolar battery cells.

[0058] As used herein, the term "control unit" 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 associated non-transient memory components in the form of memory and storage devices (read-only memory, programmable read-only memory, direct access memory, hard disk drive, etc.). The control unit 132 may also consist of several control units electrically interconnected. The control unit 132 may be connected to additional systems and / or control devices of the vehicle 100, enabling the control unit 132 to access data such as the vehicle 100's speed, acceleration, braking, and steering angle.

[0059] A processor can be a custom or off-the-shelf processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor among several processors connected to the control unit 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.

[0060] The tangible non-volatile memory 134 can include volatile and non-volatile memory, such as read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM). KAM is persistent or non-volatile memory that can be used to store various operating variables while the processor is powered off. The tangible non-volatile memory 134 can be implemented using a variety of memory devices, such as PROMs (programmable read-only memory), EPROMs (electrically erasable PROMs), EEPROMs (electrically erasable PROMs), flash memory, or other electrical, magnetic, optical, or combined memory devices capable of storing data, some of which represents executable instructions used by the control unit 132 to control various systems of the vehicle 100.

Claims

[1] Anode electrode (159) for a battery cell, comprising: an anode current collector (154) with a first surface (407); and an anode-supported electrolyte separator (160) arranged on the first surface (407), wherein the anode-supported electrolyte separator (160) comprises at least one electrolyte selected from the following compositions: a) yLi2S·(100-yx)P2S5·xP2O5 where y is in the range of 70 mol percent to 80 mol percent and x is in the range of 1 mol percent to 10 mol percent, b) Li 10 MP2S 12 where M is at least one of Si, Ge, and Sn, and c) argyrodite, which has the composition: A 12-m-x + (M m+ Y4 2- )Y 2-x 2- X x - where A + =Li + , Cu + , Ag + ; NP m+ = Si 4+ , Ge 4+ , Sn 4+ , P 5+ As 5+ ; Y 2¯ = O 2- , S 2- , Se 2- Te 2- ; X - = Cl - , Br - , I¯; and 0≤x≤2, wherein the anode-supported electrolyte separator (160) has a thickness in the range of 1 micrometer to 100 micrometers; wherein the anode-supported electrolyte separator (160) has a second surface defining a second area (406), wherein the second area (406) is larger than a third area (404) defined by a third surface (417) of an adjacent cathode (156); further comprising: an anode (158) touching the first surface (407), the anode (158) having a fourth surface (405) defining a fourth area (406), and the anode-supported electrolyte separator (160) touching the fourth surface (405); wherein a surface (402) of the anode (158) has the same size as the second surface (406) of the anode-supported electrolyte separator (160), resulting in an overhang (408) and an overlapping surface (413) of the anode (158) and the anode-supported electrolyte separator (160), which overlaps and extends beyond the third surface (404) and a perimeter (411) of the third surface (417) of the cathode (156); and wherein the overhang (408) at each point of the circumference (411) of the cathode (156) is sufficiently wide to separate the cathode (156) from the anode (158) if the anode (158) and the anode-supported electrolyte separator (160) bend and touch the cathode (156). [2] Anode electrode (159) according to claim 1, wherein the anode-supported electrolyte separator (160) contacts the first surface (407) of the anode current collector (154). [3] Anode electrode according to claim 1, wherein the anode comprises one or more active anode materials selected from the group consisting of: silicon, silicon-carbon composite, hard carbon, graphite, silicon oxide (SiOx, wherein x is either 1 or 2) and lithium titanate (LTO). [4] Anode electrode (159) according to claim 1, wherein the electrolyte is yLi2S·(100-yx)P2S5·xP2O5, wherein y is in the range of 70 mol percent to 80 mol percent and x is in the range of 1 mol percent to 10 mol percent and the electrolyte is present in the range of 50 weight percent to 99 weight percent of the total weight of the anode-supported electrolyte separator (160) and the anode-supported electrolyte separator (160) further comprises an electrolyte binder which is present in the range of 1 weight percent to 50 weight percent of the total weight of the anode-supported electrolyte separator (160). [5] Anode electrode (159) according to claim 4, wherein the electrolyte binder comprises one or more binders selected from the group consisting of: styrene butadiene rubber (SBR), hydrogenated nitrile butadiene rubber (HNBR), polyvinylidene fluoride (PVDF), poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP), polytetrafluoroethylene (PTFE) and poly(tetrafluoroethylene-co-perfluoro(3-oxa-4-pentenesulfonic acid)) lithium salt. [6] Anode electrode according to claim 1, wherein the anode-supported electrolyte separator (160) further comprises one or more liquid electrolyte diluents selected from the group consisting of: 1,1,2,2-tetrafluoroethylene, 2,2,3,3-tetrafluoropropyl ether (TTE), bis(2,2,2-trifluoroethyl) ether (BTFE), tris(2,2,2-trifluoroethyl) orthoformate (TFEO), fluorobenzene (FB), 1,2-difluorobenzene (DFB), bis(2,2-difluoroethyl) ether (BDE), 1,1,2,2-tetrafluoroethyl ether (ETE), hexafluoroisopropyl methyl ether (HFME), 1,1,2,2-tetrafluoroethyl-2,2,2-trifluoroethyl ether, 1,1,2,3,3,3-hexafluoropropyl ether, nonafluorobutyl methyl ether (mixture of isomers), difluoromethyl-2,2,3,3-tetrafluoropropyl ether, 1H,1H,5H-octafluoropentyl-1,1,2,2-tetrafluoroethyl ether (OTE), 1,1,2,3,3,3-hexafluoropropyl-2,2,2-trifluoroethyl ether, 1,1,1,2,2,3,4,5,5,5-decafluoro-3-methoxy-4-(trifluoromethyl)pentane, fluoromethyl-1,1,1,3,3,3-hexafluoroisopropyl ether, 1,1,2,3,3,3-hexafluoroisopropyl methyl ether, hexafluoroisopropyl methyl ether, methyl-2,2,3,3,3-pentafluoropropyl ether and methyl 1,1,2,2-tetrafluoroethyl ether. [7] Anode electrode (159) according to claim 1, wherein the anode-supported electrolyte separator (160) further comprises one or more ionic liquids at room temperature selected from the group consisting of: 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (EMIM-TFSI), 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (BMIM-TFSI), N-propyl-N-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide (PYR13TFSI), 1-butyl-1-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide (PYR14TFSI), 1-ethyl-3-methylimidazolium bis(fluorosulfonyl)imide (EMIM-FSI), 1-butyl-3-methylimidazolium bis(fluorosulfonyl)imide (BMIM-FSI), N-Propyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide (PYR13-FSI) and 1-butyl-1-methylpyrrolidinium bis(fluorosulfonyl)imide (PYR14-FSI). [8] Anode electrode (159) according to claim 1, wherein the anode-supported electrolyte separator (160) comprises one or more solvated ionic liquid electrolytes selected from the group consisting of: lithium triglyme bis(trifluoromethanesulfonyl)imide (Li[G3]TFSI), lithium tetraglyme bis(trifluoromethanesulfonyl)imide (Li[G4]TFSI), lithium triglyme bis(fluorosulfonyl)imide (Li[G3]FSI), lithium tetraglyme-bis(fluorosulfonyl)imide (Li[G4]FSI), lithium triglyme bis(pentafluoroethenesulfonyl)imide (Li[G3]BETI), lithium tetraglyme bis(pentafluoroethenesulfonyl)imide (Li[G4]BETI), cyclic lithium triglyme-TFSI derivative 1,2,3-Dithiazolidine-4,4,5,5-tetrafluoro-1,1,3,3-tetraoxide (Li[G3]CTFSI), cyclic lithium tetraglyme TFSI derivative 1,2,3-dithiazolidine-4,4,5,5-tetrafluoro-1,1,3,3-tetraoxide (Li[G4]CTFSI), Lithium triglyme perchlorate (Li[G3]ClO4), lithium tetraglyme perchlorate (Li[G4]ClO4), lithium triglyme tetrafluoroborate (Li[G3]BF4) and lithium tetraglyme tetrafluoroborate (Li[G4]BF4).

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