Electrochemical deposition of metal oxide coatings on cathode-active materials

Abstract

Vehicle (100), comprising: an electric motor (106) and a battery pack (108) that is electrically coupled to the electric motor (106), wherein the battery pack (108) comprises a plurality of battery cells (200), each battery cell (200) of the plurality of battery cells (200) comprising: an anode current collector (202); an anode active material layer (204) in direct contact with a surface of the anode current collector (202), wherein the anode active material layer (204) comprises anode active materials and optionally an anode binder, electrically conductive material or both the anode binder and the electrically conductive material; a cathode current collector (210); a cathode active material layer (208) in direct contact with a surface of the cathode current collector (210), wherein the cathode active material layer (208) comprises cathode active materials (302) having a metal oxide coating (304) and optionally a cathode binder, electrically conductive material, or both the cathode binder and the electrically conductive material; and a separator (206) positioned between the anode active material layer (204) and the cathode active material layer (208); characterized in that the metal oxide coating (304) TiO2 is electrochemically deposited on the cathode active materials (302), comprises a pure crystalline phase and an area of ​​the metal oxide coating (304) has a thickness variation between 5 nm and 10 nm.

Description

INTRODUCTION

[0001] The present disclosure relates to the manufacture of battery cells and, in particular, the electrochemical deposition of a metal oxide coating onto cathode active materials. Specifically, the present disclosure relates to a vehicle with an electric motor and an electrically coupled battery pack. Furthermore, the present disclosure also relates to a battery cell.

[0002] US patent 2015 / 0138530A1 discloses a battery pack made of water-based lithium-ion batteries for use in an electric vehicle. The lithium-ion batteries disclosed therein each comprise an anode current collector and a cathode current collector, each coated with active materials. The active materials can be coated with a metal oxide, such as chromium oxide, nickel oxide, or an oxide of a lanthanide.

[0003] Further lithium-based batteries are disclosed in US 2020 / 0 243 871 A1, US 2015 / 0 318 530 A1, WO 2018 / 128 742 A1, EP 4 465 383 A1 or US 2017 / 0 271 684 A1.

[0004] Lithium-ion batteries, also known as lithium-ion cells, are a type of rechargeable battery technology that has gained considerable attention due to their relatively high energy density and long lifespan compared to other battery types. The anode (negative electrode) in a lithium-ion cell is typically made of graphite, a carbon-based material capable of reversibly storing and releasing lithium ions. The cathode (positive electrode) can consist of various lithium-containing compounds such as lithium transition metal oxides (e.g., LiCoO2, LiNiMnCoO2, etc.), lithium metal phosphates (e.g., LiFePO4), or other suitable materials that can reversibly store and release lithium ions.

[0005] The electrodes in a lithium-ion cell are separated by an electrolyte, which is typically a lithium salt dissolved in an organic solvent, a solid polymer, or a solid-state electrolyte. The electrolyte serves as the medium for lithium ion transport between the anode and cathode during charging and discharging processes. Current collectors provide a conductive path for the flow of electrons between the electrodes and an external circuit. The current collector for the anode is usually made of copper or a copper alloy, while the current collector for the cathode is usually made of aluminum or an aluminum alloy.

[0006] During the discharge process, lithium ions are released from the anode and migrate through the electrolyte to be incorporated into the cathode material, while electrons flow through the external circuitry to power a device. During charging, this process is reversed, with lithium ions being removed from the cathode and deposited back into the anode.

[0007] One object of the invention is to create a vehicle with an improved and more cost-effective battery cell, as well as such a battery cell for a vehicle. SUMMARY

[0008] This problem is solved by the subject matter of independent claims 1 and 4. Advantageous further developments can be found in the dependent claims, the description, and the drawings.

[0009] According to the invention, a vehicle comprises an electric motor and a battery pack that is electrically coupled to the electric motor.The battery pack comprises a battery cell, which includes an anode current collector, an anode active material layer in direct contact with a surface of the anode current collector, wherein the anode active material layer comprises anode active materials and optionally an anode binder, electrically conductive material or both the anode binder and the electrically conductive material, a cathode current collector, a cathode active material layer in direct contact with a surface of the cathode current collector, wherein the cathode active material layer comprises cathode active materials having a metal oxide coating and optionally a cathode binder, electrically conductive material or both the cathode binder and the electrically conductive material, and a separator positioned between the anode active material layer and the cathode active material layer.The metal oxide coating is TiO2 and is electrochemically deposited onto the cathode active materials. The metal oxide coating also includes a pure crystalline phase, with the coating surface exhibiting a thickness variation between 5 nm and 10 nm.

[0010] The metal oxide coating can, purely as an example, also be in the form of MO2, where M is manganese, aluminum, zirconium, zinc, copper or magnesium.

[0011] In some embodiments, the nominal thickness of the metal oxide coating is between 5 nm and 25 nm.

[0012] In some embodiments, the metal oxide coating comprises a fused island morphology.

[0013] According to the invention, a battery cell comprises an anode current collector, an anode active material layer in direct contact with a surface of the anode current collector, wherein the anode active material layer comprises anode active materials and optionally an anode binder, electrically conductive material, or both the anode binder and the electrically conductive material, a cathode current collector, a cathode active material layer in direct contact with a surface of the cathode current collector, wherein the cathode active material comprises cathode active materials having a metal oxide coating and optionally a cathode binder, electrically conductive material, or both the cathode binder and the electrically conductive material, and a separator positioned between the anode active material layer and the cathode active material layer. The metal oxide coating is TiO2 and is electrochemically deposited onto the cathode active materials.The metal oxide coating also includes a pure crystalline phase, with an area of ​​the metal oxide coating having a thickness variation between 5 nm and 10 nm.

[0014] The metal oxide coating can, by way of example, be in the form of MO2, where M is manganese, aluminum, zirconium, zinc, copper or magnesium.

[0015] In some embodiments, the nominal thickness of the metal oxide coating is between 5 nm and 25 nm.

[0016] In some embodiments, the metal oxide coating comprises a fused island morphology.

[0017] In yet another exemplary embodiment, a method may comprise forming an anode current collector, forming an anode active material layer in direct contact with a surface of the anode current collector, wherein the anode active material layer comprises anode active materials and optionally an anode binder, electrically conductive material or both the anode binder and the electrically conductive material, forming a cathode current collector, forming a cathode active material layer in direct contact with a surface of the cathode current collector, wherein the cathode active material layer comprises cathode active materials having a metal oxide coating and optionally a cathode binder, electrically conductive material or both the cathode binder and the electrically conductive material, and forming a separator positioned between the anode active material layer and the cathode active material layer.The metal oxide coating is electrochemically deposited onto the cathode active materials.

[0018] In some embodiments, the metal oxide coating is in the form of MO2, where M is titanium, manganese, aluminum, zirconium, zinc, copper or magnesium.

[0019] In some embodiments, the metal oxide coating is TiO2.

[0020] In some embodiments, the area of ​​the metal oxide coating comprises a thickness variation between 5 nm and 10 nm. In some embodiments, the nominal thickness of the metal oxide coating is between 5 nm and 25 nm.

[0021] In some embodiments, the metal oxide coating comprises a fused island morphology.

[0022] In some embodiments, the metal oxide coating comprises a pure crystalline phase.

[0023] The aforementioned features and advantages, as well as other features and advantages of the disclosure, are readily apparent from the following detailed description in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Further features, advantages and details are listed only as examples in the following detailed description, which refers to the drawings. Fig. 1 is a vehicle configured according to one or more embodiments; Fig. 2 is an exemplary battery cell according to one or more embodiments; Fig. 3 is an electrochemical deposition system for coating a cathode active material with a metal oxide coating according to one or more embodiments; Fig. 4 is a manufacturing process for coating a cathode active material with a metal oxide coating according to one or more embodiments; Fig. 5 is a computer system according to one or more embodiments; and Fig. Figure 6 is a flowchart according to one or more embodiments. DETAILED DESCRIPTION

[0025] The following description is merely exemplary and is not intended to limit the present disclosure, its application, or its use. It is understood that in the drawings, corresponding reference numerals denote identical or corresponding parts and features.

[0026] As demand increases for energy storage systems offering higher energy densities, faster charging, and longer lifespans—driven in part by the proliferation of electric vehicles—significant challenges have been placed on the materials used in battery cell components. Research and development efforts are continuously focused on identifying novel materials and manufacturing techniques that can meet the rising demands placed on battery cells and other energy storage systems.

[0027] High-energy-density cathode active materials (CAMs), such as Ni- and Mn-rich CAMs, hold promise as next-generation cathode materials for lithium-ion batteries. However, their practical application is fraught with several challenges, including the initial irreversible capacity loss and poor cycle stability inherent in these materials. Various electrode particle coating techniques have proven to enhance the performance of cathode active materials in lithium-ion batteries, resulting in batteries with reduced capacity loss and extended lifespan. Unfortunately, while layer thicknesses can be precisely controlled in evaporation techniques like atomic layer deposition (ALD) and chemical vapor deposition (CVD), these processes are quite complex and not readily scalable.

[0028] This disclosure introduces a wet-chemical process that is cost-effective and scalable for coating CAM with a metal oxide coating. In particular, an electrochemical method for forming and / or depositing a metal oxide coating (e.g., TiO2) onto the surface of cathode particles is provided. Lithium-ion batteries manufactured using the wet-chemical processes described herein offer several advantages over previous batteries. For example, the wet-chemical processes described herein can be carried out at room temperature, with the coating layer thickness being precisely controlled by controlling the charge transfer per unit time. In other words, instead of resorting to relatively complex techniques such as ALD and CVD, an aqueous and wet-chemical electrochemical approach for the electroplating of the metal oxide coating (e.g., TiO2) onto the CAM surface is described.

[0029] A vehicle according to an exemplary embodiment is in Fig. 1 is generally specified as 100. The vehicle 100 is depicted as an automobile having a body 102. The body 102 includes a passenger compartment 104, within which a steering wheel, front seats, and rear passenger seats (not shown separately) are arranged. A number of components are arranged within the body 102, including, for example, an electric motor 106 (shown by projection under the front hood). The electric motor 106 is shown for the convenience of illustration and discussion. It is understood that the configuration, location, size, arrangement, etc., of the electric motor 106 are not to be particularly restricted, and that all such configurations (including configurations comprising multiple motors) are within the considered scope of this disclosure.

[0030] The electric motor 106 is powered by a battery pack 108 (represented by projection near the rear of the vehicle 100). The battery pack 108 is shown only for the sake of illustration and discussion. It is understood that the configuration, location, size, arrangement, etc., of the battery pack 108 are not particularly restricted and that all such configurations (including split configurations) are within the considered scope of this disclosure. Although the present disclosure is primarily discussed in connection with a battery pack 108 configured for the electric motor 106 of the vehicle 100, the aspects described herein can be similarly integrated into any system (vehicle, building, or other) that incorporates one or more energy storage systems (e.g.,one or more battery packs or modules), and all such configurations and applications that fall within the contemplated scope of this disclosure.

[0031] Fig. Figure 2 illustrates an exemplary battery cell 200 according to one or more embodiments. The battery cell 200 can be integrated as one of several battery cells in a battery pack (e.g., the battery pack 108 in Fig. 1) As in Fig. As shown in Figure 2, the battery cell 200 comprises an anode current collector 202, an anode active material layer 204, a separator 206, a cathode active material layer 208 and a cathode current collector 210, which are configured and arranged as shown.

[0032] The anode current collector 202 and the cathode current collector 210 each capture free electrons and transport them to and from an external circuit 212. In some embodiments, the external circuit 212 comprises a load device 214 (e.g., the electric motor 106 in Fig. 1) In some embodiments, the external circuit 212 and the load device 214 connect the anode active material layer 204 (via the anode current collector 202, also referred to as the negative electrode) and the cathode active material layer 208 (via the cathode current collector 210, also referred to as the positive electrode). The anode current collector 202 and the cathode current collector 210 can consist of sheets, foils (continuous or with perforations or cuts), or meshes of conductive materials. For example, the cathode current collector 210 can be made of aluminum foil, stainless steel, and / or titanium foil. Other materials are possible, such as semimetals (e.g., tin, graphite) and alloys of metals and / or semimetals thereof. In some embodiments, the cathode current collector 210 is made of aluminum foil. The anode current collector 202 can, for example, comprise a copper foil and / or one or more graphene layers.In some embodiments, the anode current collector 202 consists of copper foil. The thickness of a current collector can be approximately 10 to 20 µm, although other thicknesses are also within the scope of this disclosure.

[0033] The anode active material layer 204 is not to be understood as particularly limited and can, for example, consist of lithium metal, activated carbon powder, carbon-based materials such as graphite, silicon, silicon-based materials such as Li x Si, SiO x , LiSiO x , and nano-Si, silicon-graphite composites, tin, tin oxide (SnO2), tin-cobalt alloys, lithium titanate (Li4Ti5O) 12The anode active material layer 204 may comprise, or comprise, metal alloys such as alloys of two or more elements of tin, germanium, and cobalt, and combinations thereof. The anode active material layer 204 may further comprise electrically conductive materials such as carbon black, graphene, and / or carbon nanotubes. The anode active material layer 204 may further comprise a binder material such as poly(tetrafluoroethylene) (PTFE), sodium carboxymethylcellulose (CMC), styrene-butadiene rubber (SBR), poly(vinylidene fluoride) (PVDF), nitrile butadiene rubber (NBR), styrene-ethylene-butylene-styrene copolymer (SEBS), styrene-butadiene-styrene copolymer (SBS), lithium polyacrylate (LiPAA), sodium polyacrylate (NaPAA), sodium alginate, lithium alginate, ethylene propylene diene monomer (EPDM), and combinations thereof. The anode active material layer 204 can, for example, be greater than or equal to approximately 0 wt.% to less than or equal to approximately 20 wt.% and in certain aspects optionally greater than or equal to approximately 5 wt.%.-% to less than or equal to approximately 15 wt% of one or more binders.

[0034] As in Fig. 3 and Fig. As described in more detail in section 4, the cathode active material layer can comprise 208 cathode active materials (e.g., cathode active material 302, see section 4). Fig. 3) coated with metal oxides (i.e., CAM with metal oxide coatings). The cathode active material is not said to be particularly limited and may, for example, be nickel manganese cobalt oxide (NMC), lithium iron phosphate (LFP), nickel cobalt aluminum oxide (NCA), nickel cobalt manganese aluminum oxide (NCMA), lithium manganese iron phosphate (LMFP), lithium manganese rich (LMR), lithium manganese oxide (LMO), lithium nickel manganese oxide (LNMO), and mixtures and combinations thereof. In some embodiments, the cathode active material comprises materials having a negative electrode capacitance to positive electrode capacitance ratio (also referred to as the N to P ratio) between 1 and 3. In some embodiments, the cathode active material layer may comprise 208 nickel-manganese-cobalt (NMC) variants, such as NMC 622, NMC 811 and NMC 532.In some embodiments, the cathode active material layer 208 can comprise nickel and manganese, each in molar ratios of 30:70 to 80:20. In some embodiments, the cathode active material layer 208 can further comprise cobalt in a range between 0 and 20 percent. The cathode active material layer 208 can further comprise a binder material in a similar manner to that described for the anode active material layer 204.

[0035] Depending on the battery design (e.g., conventional vs. bipolar current collectors, etc.), the separator 206 is optional, but if present, it can be positioned to insulate the anode active material layer 204 and the cathode active material layer 208. The separator 206 also provides a minimal resistance path for the internal passage of lithium ions and, in certain cases, related anions during lithium ion cycling. The separator 206 can comprise dielectric materials such as polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), synthetic fluoropolymers such as polytetrafluoroethylene (PTFE), and composites thereof, although other dielectrics are also within the scope of this disclosure. In some embodiments, the separator 206 can include a thermally stable coating layer to improve shrinkage behavior (e.g.,a porous ceramic coating or a porous ester polymer coating, e.g., polyimide, polyamide, polyimide-polyamide copolymer (PI / PA), etc.). The thickness of separator 206 can be approximately 12 to 16 µm, although other thicknesses are also within the scope of this disclosure.

[0036] Furthermore, how best to in Fig. As shown in Figure 2, the battery cell 200 comprises an electrolyte 216. The electrolyte 216 can be a liquid electrolyte, a solid electrolyte, and / or a polymer electrolyte. In some embodiments, the electrolyte 216 is a liquid electrolyte that penetrates, partially penetrates, or covers the cathode active material layer 208, the separator 206, and / or the anode active material layer 204. In some embodiments, the electrolyte 216 comprises a lithium salt dissolved in a solvent, although other liquid electrolytes are also possible, and all such configurations are within the scope of this disclosure. The choice of the lithium salt in the electrolyte 216 is not particularly limited and can vary depending on the requirements of a particular application.In some embodiments, the lithium salt comprises, for example, lithium hexafluorophosphate (LiPF6), lithium bis(trifluoromethanesulfonyl)imide (LiTFSI), lithium bis(oxalato)borate (LiBOB), lithium difluoro(oxalato)borate (LiDFOB), lithium bis(fluorosulfonyl)imide (LiFSI), lithium trifluoromethanesulfonate (LiTf), lithium tetrafluoroborate (LiBF4), lithium nitrate (LiNO3) and / or lithium bis(pentafluoroethanesulfonyl)imide (LiBETI), and combinations thereof.

[0037] The concentration of the lithium salt(s) in electrolyte 216 depends on the chosen lithium salt(s) and the requirements of a specific application. For example, the lithium salt concentration can be varied to achieve a predetermined ionic conductivity (increasing the salt concentration leads to an increase in ionic conductivity up to a certain point, beyond which the conductivity may decrease due to increased ion-ion interactions and viscosity), or to achieve suitable levels of salt dissociation and ion mobility (for a given lithium salt, there is a minimum threshold concentration below which the salt may not dissociate completely, resulting in a deficiency of charge carriers).Conversely, there is a maximum threshold concentration beyond which the increased ion-ion interactions sufficiently hinder ion mobility (to reduce conductivity) to provide a target electrolyte viscosity, to achieve a predetermined electrochemical stability window, and / or to influence the formation and composition of the SEI layer on the lithium metal anode. In some embodiments, the lithium salts can be formed at a concentration of 0.1 M to 2 M, e.g., 0.8 M, although other concentrations are within the scope of this disclosure.

[0038] Fig. Figure 3 illustrates an electrochemical deposition system 300 for coating a cathode active material 302 with a metal oxide coating 304 according to one or more embodiments. As shown in Fig. As shown in Figure 3, the electrochemical deposition system 300 can comprise a vessel 306. In some embodiments, a conductive inner surface 308 of the vessel 306 serves as the anode 310. In some embodiments, the anode 310 is electrically coupled to a cathode 312 positioned within the vessel 306. In some embodiments, the vessel 306 is filled with a solution 314 and a solution 316, which are separated by an ion exchange membrane 318. In some embodiments, the vessel 306 can include a mixer 320 (or a stirrer, etc.) within the solution 316. In some embodiments, the speed of the mixer 320 can be controlled (see Figure 3). Fig. 5) to improve the contact between the cathode active material 302 and the anode 310.

[0039] In some embodiments, solution 314 comprises an aqueous solution of HCl(aq). In some embodiments, solution 314 is a reducing solution in which hydrogen atoms (H+, protons) are reduced at the cathode 312, producing molecular hydrogen (H2).

[0040] In some embodiments, solution 316 comprises an aqueous solution of a metal chloride (MCl₃). x ) and HCl(aq), where M is titanium, manganese, aluminum, zirconium, zinc, copper, magnesium, etc., and x is 1, 2, 3, or 4. For example, solution 316 may comprise an aqueous solution of TiCl3 / HCl(aq). Other chemical compounds include, for example, MnCl3, AlCl3, ZrCl3, CuCl3, and MgCl3. Solution 316 further comprises the cathode active material 302, which is dispersed in it. In some embodiments, solution 316 is an oxidizing solution in which the cathode active material 302 is dispersed due to the oxidation of metal ions (e.g., Ti). 3+ , if M is Ti, Mg3+ , if M is Mg, etc.) at the anode 310 (at the conductive inner surface 308) can be coated with a metal oxide coating 304. In some embodiments, the oxygen in the cathode active material 302 reacts with the metal ions during this process, causing metal oxide (MO2) to be deposited on the cathode active material 302, where M is titanium, manganese, aluminum, zirconium, zinc, copper, magnesium, etc., as already mentioned. In other words, the metal M can be derived from the metal chloride (MCl2). x ) electrochemically as a metal oxide onto the cathode active material 302 by the transfer of metal ions (e.g. Ti) 3+ ) are separated.

[0041] Coating the cathode active material 302 with the metal oxide coating 304 in this manner offers several advantages over previous methods. In particular, the cathode active material 302 can be gradually coated with the metal oxide coating 304 over time through random collisions between the cathode active material 302 and the anode 310, without the need for relatively complex vapor deposition techniques such as ALD and CVD. Furthermore, the cathode active material 302 coated with a metal oxide coating 304 using the previously described electrochemical deposition system 300 exhibits physical differences compared to cathode active materials coated with metal oxides using vapor deposition techniques. To illustrate this, we consider an example scenario in which CAM is coated with TiO2 as previously described.The particle size of the cathode active material 302 can range from 1 to 10 micrometers, and the metal oxide coating 304 can be formed with a nominal (average) thickness between 1 and 25 nm or 5 and 25 nm (taking into account a 5 nm thickness variation, as described in more detail below). However, unlike metal oxide coatings produced using vapor deposition techniques, the metal oxide coating 304 exhibits variable thickness, a distinct morphology, and a purely crystalline structure. In particular, the metal oxide coating 304 has a thickness variation between 5 nm and 10 nm, whereas vapor deposition techniques result in coatings with a thickness variation between 1 and 3 nm. In other words, the electrochemical deposition system 300 produces a metal oxide coating 304 with a relatively greater thickness variation than when using vapor deposition techniques (e.g.,The metal oxide coating 304 exhibits a thickness variation that is almost twice as large (up to more than 300 percent greater). Furthermore, the coating exhibits a fused island morphology (also known as clumping) because the metal oxides are deposited at the collision interface between the cathode active material 302 and the anode 310 (i.e., it is a non-uniform deposition process). In contrast, vapor deposition techniques such as ALD and CVD result in a uniform, layer-by-layer deposition. Finally, the metal oxide coating 304 has a 100 percent crystalline phase, in contrast to a crystalline phase of between 50 and 70 percent when using vapor deposition techniques such as ALD and CVD (with the remainder being an amorphous phase).Thus, the different thickness, the pronounced morphology and the pure crystalline structure of the metal oxide coating 304 described herein can be considered a kind of physical signature of the chemical deposition system 300 (and of the manufacturing process 400, see . Fig. 4) serve.

[0042] Fig. Figure 4 illustrates a manufacturing process 400 for coating a cathode active material 302 with a metal oxide coating 304 according to one or more embodiments. As shown in Fig. As shown in Figure 4, the manufacturing process 400 comprises steps 402, 404, 406, 408, 410 and 412, which are configured and arranged as shown.

[0043] In some embodiments, step 402 comprises suspending the cathode active material 302 (also referred to as electrode material particles) in an aqueous electrolyte solution (e.g., solution 316 of Fig. 3) In some embodiments, the cathode active material 302 is suspended in the solution 316 at a temperature between about 20 degrees Celsius and 80 degrees Celsius, although other temperatures are also within the scope of this disclosure, which are subject only to the aqueous electrolyte limits of the solution 316 chosen for a particular application (e.g., about 0 degrees Celsius to about 100 degrees Celsius for most electrolyte solutions).

[0044] In some embodiments, the cathode-active material 302 is dispersed in the solution 316 at a predetermined pH value, which is selected such that a predetermined metal oxide structure and / or phase is achieved in the resulting metal oxide coating 304. In some embodiments, the cathode-active material 302 is dispersed in the solution 316 at a predetermined pH value between 1 and 7, more precisely between 1 and 3, whereby it is understood that the pH value varies depending on the selection of the metal oxide coating 304.

[0045] In some embodiments, step 404 includes applying a current and / or voltage to the solution 316. In some embodiments, step 404 includes applying a current and / or voltage to the anode 310 and the cathode 312 of the electrochemical deposition system 300 (see Fig. 3) The voltage, current, and / or current density vary depending on the deposited material, the desired deposition thickness, and the reactor (vessel) design. The voltage, current, and / or current density can be kept constant or varied as desired to control the nominal thickness of the metal oxide coating 304 deposited onto the cathode active material 302, with relatively higher voltages, currents, and / or current densities resulting in relatively thicker coatings and vice versa.

[0046] In some embodiments, step 406 comprises maintaining the current and / or voltage for a predetermined time and / or a time required to achieve a desired thickness of the metal oxide coating 304. In some embodiments, samples are taken from the solution 316 and the thickness of the metal oxide coating 304 is determined empirically. In some embodiments, the thickness of the metal oxide coating 304 is estimated using prior empirically derived data (e.g., thickness vs. time vs. current profiles from previous processes).

[0047] In some embodiments, step 408 includes filtering and rinsing the cathode active material 302 coated with the metal oxide coating 304. The cathode active material 302 coated with the metal oxide coating 304 can be filtered from the solution 316 physically and / or chemically as desired. In this way, the cathode active material 302 coated with the metal oxide coating 304 can be separated from the solution 316, and the electrode fabrication and assembly of the cell can be continued in step 412.

[0048] In some embodiments, step 410 includes the reuse of solution 316 (once the cathode active material 302 coated with the metal oxide coating 304 has been separated in step 408). In some embodiments, the filtered solution 316 can be recycled to the electrochemical deposition system 300 (see Figure 3). Fig. 3).

[0049] In some embodiments, step 412 includes the fabrication of a battery cell in which the cathode active material 302 coated with the metal oxide coating 304 is partially used. Step 412 may, for example, include the fabrication and / or procurement of current collectors, separators, electrolytes, etc. (see Fig. 2).

[0050] Fig. Figure 5 illustrates aspects of an embodiment of a computer system 500 that can perform various aspects of the embodiments described herein. In some embodiments, the computer system(s) 500 can be located within or in combination with the electrochemical deposition system 300 (see Figure 5). Fig. 3) and / or the manufacturing process 400 (see Fig. 4) be implemented and / or otherwise integrated. In some embodiments, the computer system 500 can, for example, control a temperature, pressure, voltage, current, stirring speed, etc. of the electrochemical deposition system 300 during the manufacturing process 400.

[0051] The computer system 500 comprises at least one processing device 502, which generally includes one or more processors or processing units for performing a plurality of functions, such as all and / or any functions relating to Fig. 7. Components of the computer system 500 also include a system memory 504 and a bus 506 that connects various system components, including the system memory 504, to the processing device 502. The system memory 504 can comprise a plurality of media readable by the computer system. These media can be any available medium accessible to the processing device 502, including volatile and non-volatile media, as well as removable and non-removable media. For example, the system memory 504 includes non-volatile memory 508, such as a hard disk, and can also include volatile memory 510, such as random-access memory (RAM) and / or cache memory. The computer system 500 can further comprise other removable / non-removable, volatile / non-volatile storage media of the computer system.

[0052] The system memory 504 can comprise at least one program product, which has a set (e.g., at least one) of program modules configured to perform functions of the embodiments described herein. For example, the system memory 504 stores various program modules that generally perform the functions and / or procedures of the embodiments described herein. One or more modules 512, 514 can be used to perform functions related to the block diagrams described herein. The computer system 500 is not so limited, as other modules may also be included depending on the desired functionality of the computer system 500.As used herein, the term “module” refers to a processing circuit that may include an application-specific integrated circuit (ASIC), an electronic circuit, a processor (common, dedicated or group) and memory that executes one or more software or firmware programs, a combinational logic circuit and / or other suitable components that provide the functionality described.

[0053] The processing device 502 can also be configured to communicate with one or more external devices 516, such as a keyboard, a pointing device, and / or other devices (e.g., a network card, a modem, etc.), enabling the processing device 502 to communicate with one or more other computing devices. Communication with various devices can be effected via the input / output (I / O) interfaces 518 and 520.

[0054] The processing device 502 can also communicate with one or more networks 522, such as a local area network (LAN), a wide area network (WAN), a bus network, and / or a public network (e.g., the Internet), via a network adapter 524. In some embodiments, the network adapter 524 is or includes an optical network adapter for communication over an optical network. It is understood that other hardware and / or software components may also be used in conjunction with the computer system 500, even if not shown. Examples include, but are not limited to, microcode, device drivers, redundant processing units, external hard disk arrays, RAID systems, data archiving systems, etc.

[0055] With the following reference to Fig. Figure 6 shows a flowchart 600 for the electrochemical deposition of a metal oxide coating on cathode-active materials in general according to one embodiment. The flowchart 600 is presented with reference to Fig. 1-5 described, and can be found in Fig. 6 additional steps not shown. Although shown in a specific order, the steps in Fig. The 6 blocks shown can be rearranged, subdivided and / or combined.

[0056] In block 602, the process includes the formation of an anode current collector.

[0057] In Block 604, the method comprises forming an anode active material layer in direct contact with a surface of the anode current collector. In some embodiments, the anode active material layer comprises anode active materials and optionally an anode binder, electrically conductive material, or both the anode binder and the electrically conductive material.

[0058] In block 606, the process includes the formation of a cathode current collector.

[0059] In Block 608, the method comprises forming a cathode active material layer in direct contact with a surface of the cathode current collector. In some embodiments, the cathode active material layer comprises cathode active materials with a metal oxide coating and optionally a cathode binder, an electrically conductive material, or both the cathode binder and the electrically conductive material.

[0060] In block 610, the process includes forming a separator that is positioned between the anode active material layer and the cathode active material layer.

[0061] In some embodiments, the metal oxide coating is in the form of MO2, where M is titanium, manganese, aluminum, zirconium, zinc, copper or magnesium.

[0062] In some embodiments, the metal oxide coating is TiO2.

[0063] In some embodiments, the area of ​​the metal oxide coating comprises a thickness variation between 5 nm and 10 nm. In some embodiments, the nominal thickness of the metal oxide coating is between 5 nm and 25 nm.

[0064] In some embodiments, the metal oxide coating comprises a fused island morphology.

[0065] In some embodiments, the metal oxide coating comprises a pure crystalline phase.

[0066] The terms "a" and "an" do not imply a limitation of quantity, but rather denote the presence of at least one of the mentioned items. The term "or" means "and / or" unless the context clearly indicates otherwise. When the entire description refers to "an aspect," this means that a particular element (e.g., a feature, a structure, a step, or a property) described in connection with the aspect is encompassed in at least one of the aspects described herein and may or may not be present in other aspects. Furthermore, it is understood that the described elements can be combined in any suitable way across the various aspects.

[0067] Additionally, as used in this disclosure, expressions of the form "at least one of A, B, or C," "at least one of A, B, and C," and the like should be understood to mean that at least one is selected from the group comprising "A, B, and C." Unless expressly stated otherwise in the context of a particular instance in this disclosure, this wording does not mean "at least one of A, at least one of B, and at least one of C." As used in this disclosure, the example "at least one of A, B, or C" would cover any of the following selections: {A}, {B}, {C}, {A, B}, {A, C}, {B, C}, and {A, B, C}.

[0068] When an element such as a layer, film, area, or substrate is described as lying "on" another element, it may lie directly on top of the other element, or there may be intermediate elements. Conversely, when an element is described as lying "directly on" another element, there are no intermediate elements.

[0069] Unless otherwise specified herein, all testing standards are the latest standard in force on the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the testing standard appears.

[0070] Unless otherwise defined, the technical and scientific terms used herein have the same meanings as generally understood by an expert in the field to which this disclosure relates.

Claims

[1] Vehicle (100), comprising: an electric motor (106) and a battery pack (108) that is electrically coupled to the electric motor (106), wherein the battery pack (108) comprises a plurality of battery cells (200), each battery cell (200) of the plurality of battery cells (200) comprising: an anode current collector (202); an anode active material layer (204) in direct contact with a surface of the anode current collector (202), wherein the anode active material layer (204) comprises anode active materials and optionally an anode binder, electrically conductive material or both the anode binder and the electrically conductive material; a cathode current collector (210); a cathode active material layer (208) in direct contact with a surface of the cathode current collector (210), wherein the cathode active material layer (208) comprises cathode active materials (302) having a metal oxide coating (304) and optionally a cathode binder, electrically conductive material, or both the cathode binder and the electrically conductive material; and a separator (206) positioned between the anode active material layer (204) and the cathode active material layer (208); characterized by , that the metal oxide coating (304) TiO2 is electrochemically deposited on the cathode active materials (302), comprises a pure crystalline phase and an area of ​​the metal oxide coating (304) has a thickness variation between 5 nm and 10 nm. [2] Vehicle (100) according to claim 1, wherein a nominal thickness of the metal oxide coating (304) is between 5 nm and 25 nm. [3] Vehicle (100) according to claim 1, wherein the metal oxide coating (304) has a fused island morphology. [4] Battery cell (200), comprising: an anode current collector (202); an anode active material layer (204) in direct contact with a surface of the anode current collector (202), wherein the anode active material layer (204) comprises anode active materials and optionally an anode binder, electrically conductive material or both the anode binder and the electrically conductive material; a cathode current collector (210); a cathode active material layer (208) in direct contact with a surface of the cathode current collector (210), wherein the cathode active material layer (208) comprises cathode active materials (302) having a metal oxide coating (304) and optionally a cathode binder, electrically conductive material, or both the cathode binder and the electrically conductive material; and a separator (206) positioned between the anode active material layer (204) and the cathode active material layer (208); characterized by , that the metal oxide coating (304) TiO2 is electrochemically deposited on the cathode active materials, comprises a pure crystalline phase and an area of ​​the metal oxide coating (304) has a thickness variation between 5 nm and 10 nm.

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