Rechargeable battery with a hybrid cathode comprising a conversion and intercalation active material

Abstract

A rechargeable battery is disclosed. The rechargeable battery includes an anode, a cathode including a lithium-ion intercalation host, and an electrolyte including a solvent and a halogen-containing compounding that functions as an active cathode conversion material, and the electrolyte is in contact with the anode and the cathode.

Description

Technical Field

[0001] The present invention generally relates to the field of energy storage devices, and more particularly to an energy storage device having a cathode formed from a plurality of active materials including at least one active material utilizing a chemical conversion mechanism for storing energy and at least one other active material utilizing an ion-intercalation mechanism for storing energy.

Background Art

[0002] A secondary energy storage device, or simply a rechargeable battery, is an energy storage device that can be electrically recharged to its initial pre-discharge state after use by passing a current in a direction opposite to the current discharging through the circuit. Energy storage devices such as lithium-ion batteries have a high energy density and can provide a compact rechargeable energy source suitable for use in portable electronic devices, electric transportation, and renewable energy storage. Rechargeable batteries using metallic lithium as the anode active material enable a higher energy density than current state-of-the-art lithium-ion batteries that utilize graphite for this purpose.

[0003] There is a high demand for rechargeable batteries for a wide range of applications, from small batteries for industrial and medical devices to larger batteries for electric vehicles (EVs) and grid energy storage systems. Each application requires a specific set of electrochemical performance characteristics, and in many important and growing current applications such as EVs, battery performance is still considered a major limiting factor for meeting high performance standards that meet customer needs.

[0004] Currently, two types of rechargeable batteries that are typically discussed in both academia and industry are batteries that operate via electrochemical intercalation / deintercalation of active ions and batteries that operate via conversion of active electrode / electrolyte materials. The most widely used rechargeable battery (excluding lead-acid batteries used in vehicles with internal combustion engines) is the lithium-ion battery (LIB). Generally, today's most commercial LIBs use a lithium intercalation material based on metal oxides or metal phosphates as the positive electrode and a carbon graphite-based intercalation material as the negative electrode, and lithium ions are reciprocally moved between them through a liquid electrolyte when the battery is charged and discharged.

[0005] Despite the rapid growth and success of LIBs, several drawbacks remain to be overcome to meet the market's demand for rapidly increasing higher-performance batteries. Cathode materials with relatively low energy density and high cost, such as cobalt and nickel, have been one of the biggest problems hindering the advancement of lithium-ion batteries to a wider range of applications. However, it is widely understood that science and technology are approaching the limits of what is possible to push up the specific energy and energy density of lithium-ion batteries, as lithium-ion batteries are approaching and in some cases even exceeding the specific energy target of 300 watt-hours per kilogram (Wh / kg). Summary of the Invention Problems to be Solved by the Invention

[0006] As recognized by the present invention, what is needed is a lithium-ion battery having a cathode of higher energy density formed from a less expensive cathode material. Embodiments of the present invention provide a method of increasing the energy density and / or reducing the cost of the cathode of a rechargeable lithium-ion battery by hybridizing a traditional lithium-ion intercalation cathode material with a conversion cathode material of a halogen or metal halide to form an improved cathode, and a hybrid energy storage device resulting therefrom.

Means for Solving the Problems

[0007] According to at least one embodiment of the present invention, the drawbacks and additional advantages of current lithium-ion batteries are provided through a dissolved-phase hybrid cathode lithium-ion battery (also sometimes referred to herein as a first rechargeable battery). The dissolved-phase hybrid cathode lithium-ion battery includes an anode, a cathode including a lithium-ion intercalation host, and an electrolyte including a solvent and a first halogen-containing compound that functions as an active cathode conversion material, the electrolyte being in contact with the anode and the cathode.

[0008] In certain embodiments, the cathode further includes a second halogen-containing compound that functions as an active cathode conversion material.

[0009] In certain embodiments, the first halogen-containing compound that functions as an active cathode conversion material included in the electrolyte is the same as the second halogen-containing compound that functions as an active cathode conversion material included in the cathode.

[0010] In certain embodiments, the first halogen-containing compound that functions as an active cathode conversion material included in the electrolyte is different from the second halogen-containing compound that functions as an active cathode conversion material included in the cathode.

[0011] In one embodiment, the halogen-containing compound that functions as the active cathode conversion material contained in the electrolyte is a metal halide.

[0012] In one embodiment, the metal halide dissociates in the solvent into respective halide ions and respective metal ions, and the halide ions include at least one of I - , Br - , Cl - , or F - , and the metal ions include at least one of Li + , Al 3+ , Mg 2+ , or Na + .

[0013] In one embodiment, the lithium-ion intercalation host is selected from the group consisting of lithium cobalt oxide, nickel cobalt aluminum, lithium ion manganese oxide, lithium nickel manganese cobalt oxide, nickel cobalt manganese oxide, lithium iron phosphate, and mixtures and combinations thereof.

[0014] In one embodiment, the solvent of the electrolyte is selected from the group consisting of carbonate compounds, heterocyclic compounds, ethers, esters, cyclic ethers, cyclic esters, nitriles, ether nitriles, and mixtures and combinations thereof.

[0015] In one embodiment, the dissolved-phase hybrid cathode lithium-ion battery further includes one or more oxidizing gases selected from the group consisting of air, oxygen, nitrogen oxide, nitrogen dioxide, and mixtures and combinations thereof.

[0016] According to at least one embodiment of the present invention, the drawbacks and additional advantages of current lithium-ion batteries are provided through a solid-phase hybrid cathode lithium-ion battery (which may also be referred to herein as a second rechargeable battery). A solid-phase hybrid cathode lithium-ion battery is disclosed. The solid-phase hybrid cathode lithium-ion battery includes an anode, a lithium-ion intercalation host, a cathode including a halogen-containing compound that functions as an active cathode conversion material, and an electrolyte including a solvent and a lithium-containing compound, wherein the electrolyte contacts the anode and the cathode.

[0017] In one embodiment, the halogen-containing compound that functions as the active cathode conversion material included in the cathode of the solid-phase hybrid cathode lithium-ion battery is a halogen or a metal halide.

[0018] The metal halide includes respective halide ions and respective metal ions, and the halide ions include at least one of I - , Br - , Cl - or F - , and the metal ions include at least one of Li + , Al 3+ , Mg 2+ or Na + .

[0019] In one embodiment, the lithium-containing compound included in the electrolyte is a lithium salt.

[0020] In one embodiment, the lithium-ion intercalation host is selected from the group consisting of lithium cobalt oxide, nickel cobalt aluminum, lithium ion manganese oxide, lithium nickel manganese cobalt oxide, nickel cobalt manganese oxide, lithium iron phosphate, and mixtures and combinations thereof.

[0021] In certain embodiments, the solvent of the electrolyte is selected from the group consisting of carbonate compounds, heterocyclic compounds, ethers, esters, cyclic ethers, cyclic esters, nitriles, ether nitriles, and mixtures and combinations thereof.

[0022] In certain embodiments, the solid-phase hybrid cathode lithium-ion battery further comprises one or more oxidizing gases selected from the group consisting of air, oxygen, nitrogen oxide, nitrogen dioxide, and mixtures and combinations thereof.

[0023] According to at least one embodiment of the present invention, the drawbacks and additional advantages of current lithium-ion batteries are provided through a method of forming a dissolved-phase hybrid cathode lithium-ion battery (i.e., a first rechargeable battery). The method includes coating a slurry comprising a lithium-containing intercalation material onto a cathode current collector. Further, the method includes dissolving a cathode conversion material comprising at least one of a metal halide or a halogen in a solvent to form a solution. Further, the method includes stacking an anode, a separator, and the cathode current collector to form a dissolved-phase hybrid cathode lithium-ion battery. The dissolved-phase hybrid cathode lithium-ion battery includes the anode, an electrolyte comprising the solution, the separator, and the cathode current collector coated with the slurry, and the at least one of the metal halide or the halogen of the electrolyte functions as an active cathode conversion material.

[0024] In certain embodiments, the method includes adding a second halogen or metal halide to the cathode, and the second halogen or metal halide also functions as an active cathode conversion material.

[0025] In one embodiment, the second halogen or metal halide added to the cathode is the same as the halogen or metal halide contained in the electrolyte.

[0026] In one embodiment, the second halogen or metal halide added to the cathode is different from the halogen or metal halide contained in the electrolyte.

[0027] In one embodiment, the method includes replacing a portion of the lithium-ion intercalation material with a second metal halide or halogen, and the second metal halide or halogen also functions as an active cathode conversion material.

[0028] In one embodiment, the second metal halide or halogen that replaces a portion of the lithium-ion intercalation material is the same as the halogen or metal halide contained in the electrolyte.

[0029] In one embodiment, the second metal halide or halogen that replaces a portion of the lithium-ion intercalation material is different from the halogen or metal halide contained in the electrolyte.

[0030] According to at least one embodiment of the present invention, the drawbacks and additional advantages of current lithium-ion batteries are provided through a solid-phase hybrid cathode lithium-ion battery. The method includes coating a slurry including at least one of a halogen or a metal halide and a lithium-ion intercalation material on a cathode current collector. Further, the method includes dissolving a lithium salt in a solvent to form an electrolyte. Further, the method includes stacking an anode, a separator, and the cathode current collector to form a solid-phase hybrid cathode lithium-ion battery. The solid-phase hybrid cathode lithium-ion battery includes the anode, the electrolyte, the separator, and the cathode current collector coated with the slurry, and the at least one of the halogen or the metal halide of the slurry functions as an active cathode conversion material.

[0031] The drawings included in this disclosure are incorporated into and form a part of the specification. They illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. These drawings are only illustrative of specific embodiments and do not limit the invention.

Brief Description of the Drawings

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[0033] The present invention generally relates to the field of energy storage devices, and more particularly to an energy storage device having a cathode formed from a plurality of active materials including at least one active material that utilizes a chemical conversion mechanism for storing energy and at least one other active material that utilizes an ion intercalation mechanism for storing energy.

[0034] Embodiments of the present invention provide a method for increasing the energy density and / or reducing the cost of a cathode of a rechargeable lithium battery by hybridizing a traditional lithium-ion intercalation cathode material with a cathode conversion material of a halogen or metal halide to form an improved cathode, and an energy storage device resulting therefrom. According to embodiments of the present invention, an energy storage device is provided having a hybrid cathode in which the addition of a halogen or metal halide conversion material (e.g., iodine (I2) or lithium iodide (LiI)) enhances the energy density of a traditional metal ion intercalation cathode (e.g., lithium nickel manganese cobalt oxide (Li-NMC), lithium cobalt oxide (LCO), lithium iron phosphate (LFP)).

[0035] There are two motivations behind creating a hybrid cathode material formed from a lithium-ion intercalation material and a halogen or metal halide conversion material. First, embodiments of the present invention recognize that the cost of cathodes formed in part from cobalt and / or nickel continues to increase, and the market for these metals is often highly volatile. In addition, there are supply chain issues associated with cobalt and nickel due to additional environmental stability measures taken to mine these metals. Embodiments of the present invention provide a hybrid energy storage device in which cost is reduced and environmental impact is improved by producing a hybridized cathode formed from a halogen or metal halide conversion material and an NMC or LCO-based intercalation cathode. It should be recognized that by replacing portions of cobalt and / or nickel used in cathode formation with lower-cost and more environmentally sustainable halogen or metal halide conversion materials, a hybrid energy storage device can be achieved having an energy density similar to and / or exceeding that of current lithium-ion batteries having cathodes formed purely from NMC or LCO.

[0036] Second, embodiments of the present invention recognize that while lithium-ion batteries having cathodes formed purely from iron phosphate are already very cost-beneficial, their energy density (theoretical specific capacity is ~170 mAh / g) is lower than that of lithium-ion batteries having cathodes formed purely from NMC or LCO. This lower energy density significantly limits the range of applications for which lithium-ion batteries having cathodes formed from iron phosphate can be used. Embodiments of the present invention provide lithium-ion batteries with increased energy density having cathodes formed from iron phosphate while maintaining relatively low manufacturing costs by producing a hybridized cathode formed from a halogen or metal halide conversion material and LFP. It should be recognized that by replacing a portion of the iron phosphate used in forming the cathode with a halogen or metal halide conversion material, a more inexpensive and environmentally sustainable hybrid energy storage device with increased energy density is achieved.

[0037] According to one embodiment of the present invention, a lithium-ion battery with a solid-phase hybrid cathode is formed from an intercalation material and a halogen or metal halide-based conversion material. Both the intercalation material and the halogen or metal halide-based conversion material are prepared as a slurry, and the slurry is coated onto a current collector. According to another embodiment of the present invention, a lithium-ion battery with a 'dissolved phase' or 'liquid phase' hybrid cathode is formed from an intercalation material and a halogen or metal halide-based cathode conversion material. Only the intercalation material is prepared as a slurry and coated onto a current collector, and the halogen or metal halide-based cathode conversion material is solubilized into an electrolyte with one or more additional ionic salts. Here, the halogen or metal halide-based cathode conversion material serves a dual role, both as an electrolyte (promoting lithium-ion transport) and as an active cathode conversion material.

[0038] Descriptions of various embodiments of the present invention are provided for illustrative purposes, but are not intended to be exhaustive or limiting of the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope of the described embodiments. The terms used herein are selected to best explain the principles of the embodiments, practical applications, or technological improvements over technologies found in the market, or to enable other skilled artisans in the art to understand the embodiments disclosed herein.

[0039] The present invention will be described in detail below with reference to the drawings. FIG. 1 is a conceptual diagram illustrating an example of a solid-phase hybrid cathode battery (hereinafter, referred to as battery 100 as a whole and indicated by its number) according to at least one embodiment of the present invention. FIG. 1 provides an illustration of only one implementation and does not imply any limitation regarding the environment in which different embodiments may be implemented. Those skilled in the art can make many modifications to the illustrated environment without departing from the scope of the present invention as recited by the claims.

[0040] Battery 100 includes an anode current collector 110, an anode 112, an electrolyte 114, a separator 116, a cathode 118, and a cathode current collector 120. Battery 100 operates via a reduction-oxidation (redox) reaction. For example, battery 100 utilizes different oxidation states and redox reactions of one or more components or elements to charge and discharge battery 100.

[0041] The anode current collector 110 can include a material with suitable electrical conductivity that collects electrons generated by the redox reaction during discharge of the battery 100 and provides a conductive path to an external circuit to which the battery 100 is connected. Similarly, during recharge of the battery 100, the anode current collector 110 provides an electrical path between an external voltage source and the anode 112 that supplies a voltage for another redox reaction to charge the battery 100. The anode current collector 110 can be formed from any material that achieves stability or passivation at the respective electrochemical potential of the anode 112. In certain embodiments, the anode current collector 110 can include a woven or non-woven metal fiber, a metal foam, a metal foil, or a woven or non-woven carbon fiber. In certain embodiments, the anode current collector 110 can include, additionally or alternatively, a stainless steel mesh, a copper (Cu) mesh, a nickel (Ni) foam, and / or a carbon paper. For example, the anode current collector 110 can include a stainless steel mesh with carbon nanoparticles deposited thereon. In another example, the anode current collector 110 can be a conductive porous material.

[0042] The anode 112 extracts metal ions from the electrolyte 114 during charging and releases metal ions to the electrolyte 114 during discharge. The anode 112 can be any anode. For example, the anode 112 can be formed from, but is not limited to, lithium, magnesium, sodium, or any possible combination thereof. In some embodiments, the anode 112 consists essentially of elemental lithium, magnesium, or sodium, or lithium, magnesium, or sodium alloyed with one or more additional elements. In certain embodiments, the anode 112 is lithium metal.

[0043] The electrolyte 114 includes at least one solvent and at least one lithium-containing compound. In some embodiments, the at least one solvent of the electrolyte 114 can be selected from the group consisting of, but not limited to, carbonate compounds, heterocyclic compounds, ethers, esters, cyclic ethers, cyclic esters, nitriles, and mixtures and combinations thereof. In some embodiments, the at least one solvent of the electrolyte 114 can further be selected from, for example, non-aqueous, ethers, glymes, carbonates, nitriles, amides, amines, organic sulfur solvents, organic phosphoric acid solvents, organic silicon solvents, fluorinated solvents, adiponitrile (ADN), propylene carbonate (PC), dioxolane, dimethoxyethane (DME) and other organic solvents, and mixtures and combinations thereof. In one embodiment, the electrolyte 114 includes a solvent containing 1,3-dioxolane and 1,2-dimethoxyethane in equal amounts. In one embodiment, the lithium-containing compound is a lithium salt such as lithium bis(trifluoromethanesulfonyl)imide or LiTFSI. In one embodiment, the electrolyte 114 further includes at least one salt. For example, the salt can be provided by the lithium-containing compound of the electrolyte 114 such as LiTFSI.

[0044] In some embodiments, electrolyte 114 further includes one or more oxidizing gases. In certain embodiments, electrolyte 114 can be placed in the presence of an oxidizing gas, and the expression “including an oxidizing gas” is intended to include such a configuration. In certain embodiments, one or more oxidizing gases can be dissolved in a solvent including at least one salt of electrolyte 114 and at least one lithium-containing compound. In certain embodiments, the oxidizing gas can include, but is not limited to, at least one of air, oxygen, nitrogen oxide, nitrogen dioxide, or mixtures and combinations thereof. The oxidizing gas can assist in inducing the redox reaction of battery 100 as described above and in achieving a highly reversible redox reaction, contributing to enhancing the electrochemical performance of battery 100. The oxidizing gas can assist in inducing such a redox reaction, but it should be noted that the oxidizing gas is not consumed or released during the use of battery 100 (i.e., the oxidizing gas does not participate in the redox reaction of battery 100).

[0045] Separator 116 provides a barrier that electronically insulates between anode 112 and cathode 118, thereby forcing the flow of electrons through the external electrical circuit to which battery 100 is connected. Thus, electrons do not move through battery 100 (e.g., through electrolyte 114 of battery 100), but nevertheless allow metal ions to flow through battery 100 during charging and discharging. In various embodiments, separator 116 can be subjected to coating with electrolyte 114, immersion in electrolyte 114, placement within electrolyte 114, or enclosure / subsmergence by electrolyte 114. In certain embodiments, separator 116 includes a non-conductive material to prevent the movement of electrons through battery 100 and instead allow electrons to move through the external circuit. For example, separator 116 can include glass, fibrous non-woven fabric, polymer film, or rubber.

[0046] The cathode 118 includes an active cathode conversion material (herein, interchangeably also referred to as 'cathode conversion material' or simply 'conversion material') and a lithium-ion intercalation host (herein, interchangeably also referred to as 'cathode intercalation material' or simply 'intercalation material'). In some embodiments, the active cathode conversion material is a molecular halogen. For example, the molecular halogen can be selected from, but is not limited to, F2, Cl2, Br2, and I2. In some embodiments, the active cathode conversion material is a metal halide (e.g., MX represented by M as a metal element and X as a halogen element). In one embodiment, the metal halide can be dissolved in a solvent and dissociated into respective metal ions and respective halide ions. In one embodiment, the metal ions can be selected from, but are not limited to, Li + 、Al 3+ 、Mg 2+ 、or Na + of at least one (e.g., M can be Li, Al, Mg, or Na), and the halide ions can include ions selected from, but are not limited to, I - 、Br - 、Cl - 、or F - of at least one (e.g., X can be I, Br, Cl, or F). In some embodiments, the active cathode conversion material is an organic halogen compound (e.g., AX represented by A as an organic species with a positive charge and X as a halogen element with a negative charge). In one embodiment, the organic halogen compound can be dissolved in a solvent and dissociated into respective organic cations and respective halide anions. In one embodiment, the organic cations can be selected from, but are not limited to, at least one of ammonia, alkylammonium, imidazolium, or pyrrolidinium, and the halide anions can be selected from, but are not limited to, I - 、Br - 、Cl - 、or F- It can contain ions selected from at least one of them (for example, X can be I, Br, Cl, or F).

[0047] In certain embodiments, the lithium-ion intercalation host is a metal oxide compound. For example, the lithium-ion intercalation host can be, but is not limited to, lithium cobalt oxide (LCO) (for example, LiCoO2), nickel cobalt aluminum (NCA) (for example, LiNi x Co y Al z O2, LiNi 0.8 Co 0.15 Al 0.05 O2), lithium ion manganese oxide (LMO) (for example, LiMn2O4), lithium nickel manganese cobalt oxide (NMC) (for example, LiNiMnCoO2), nickel cobalt manganese oxide (NCM) (for example, LiNi x Co y Mn z O2, LiNi 0.33 Co 0.33 Mn 0.33 O2), lithium iron phosphate (LFP, for example, LiFePO4), and can be selected from mixtures and combinations thereof.

[0048] The cathode 118 is in electrochemical and / or physical contact with the cathode current collector 120. In some embodiments, the cathode 118 of the battery 100 is in a viscous or slurry state. In other embodiments, the cathode 118 of the battery 100 is placed in a solid phase. In embodiments where the cathode 118 remains in a solid phase, the density of the cathode 118 does not necessarily have to be greater than the density of the cathode current collector 120. In certain embodiments, the cathode 118 is initially formed in a viscous or slurry state, coated on at least the bottom surface of the cathode current collector 120, and cured to form the final solid cathode.

[0049] The cathode current collector 120 can include a material with appropriate electrical conductivity that collects the electrons generated by the redox reaction during discharge of the battery 100 and provides a conductive path to an external circuit to which the battery is connected. Similarly, during recharging of the battery 100, the cathode current collector 120 provides an electrical path between an external voltage source and the cathode 118 that supplies a voltage for another redox reaction to charge the battery 100. The cathode current collector 120 can be formed from any material that achieves stability or passivation at the respective electrochemical potential of the cathode 118. In some embodiments, the cathode current collector 120 can include a metallic fiber woven or non-woven fabric, a metallic foam, a metallic foil, or a carbon fiber woven or non-woven fabric. In some embodiments, the cathode current collector 120 can include, additionally or alternatively, a stainless steel mesh, an aluminum (Al) mesh, a nickel (Ni) foam, and / or carbon paper. For example, the cathode current collector 120 can include a stainless steel mesh with aluminum nanoparticles deposited thereon. In another example, the cathode current collector 120 can be a conductive porous material.

[0050] In some embodiments, the battery 100 has a closed volume. For example, the anode current collector 110, the anode 112, the electrolyte 114, the separator 116, the cathode 118, and the cathode current collector 120 are housed within an encapsulating cell or other enclosure. In this way, one or more oxidation additives within the battery 100 remain confined within the battery 100. In other embodiments, the battery 100 has a substantially closed volume. For example, the anode current collector 110, the anode 112, the electrolyte 114, the separator 116, the cathode 118, and the cathode current collector 120 are housed within a substantially encapsulating cell or other enclosure. In this way, removal and / or addition of one or more oxidation additives from / to the battery 100 is possible.

[0051] Figure 2 is a conceptual diagram illustrating battery 100 of FIG. 1 within encapsulated cell system 200. Figure 2 provides an illustration of only one implementation and does not imply any limitation regarding the environment in which different embodiments may be implemented. Those skilled in the art can make many modifications to the illustrated environment without departing from the scope of the invention as recited by the claims.

[0052] Encapsulated cell system 200 can include a cell that houses battery 100 during operation of battery 100, a cell used in the manufacture of battery 100, or both. For example, encapsulated cell system 200 can include cells available from Swagelok Company of Solon, Ohio, under the trade designation "SWAGELOK" and can be used in the manufacture of battery 100. In one embodiment, encapsulated cell system 200 can include inlet tube 210 and / or outlet tube 220. Inlet tube 210 and outlet tube 220 can be used for the introduction and discharge of encapsulated cell system 200 of oxidation additives including, but not limited to, air, oxygen, nitrogen oxides, nitrogen dioxide, and mixtures and combinations thereof.

[0053] Figure 3 is a conceptual diagram illustrating an example of a dissolved-phase hybrid cathode battery (hereinafter referred to as battery 300 in its entirety and indicated by its number) according to at least one embodiment of the present invention. Figure 3 provides an illustration of only one implementation and does not imply any limitation regarding the environment in which different embodiments may be implemented. It is considered that those skilled in the art can make many modifications to the illustrated environment without departing from the scope of the invention as recited by the claims.

[0054] The battery 300 includes an anode current collector 310, an anode 312, an electrolyte 314, a separator 316, a cathode 318, and a cathode current collector 320. The battery 300 operates via a reduction-oxidation (redox) reaction. For example, the battery 300 utilizes different oxidation states and redox reactions of one or more components or elements to charge and discharge the battery 300.

[0055] The anode current collector 310 can include a material with suitable electrical conductivity that collects electrons generated by the redox reaction during discharge of the battery and provides an electrical conduction path to an external circuit to which the battery 300 is connected. Similarly, during recharge of the battery 300, the anode current collector 310 provides an electrical path between an external voltage source and the electrolyte 314 that supplies a voltage for another redox reaction to charge the battery 300. The anode current collector 310 can be formed from any material that achieves stability or passivation at the respective electrochemical potential of the anode 312. In certain embodiments, the anode current collector 310 can include a woven or non-woven metal fiber, a metal foam, a metal foil, or a woven or non-woven carbon fiber. In certain embodiments, the anode current collector 310 can additionally or alternatively include a stainless steel mesh, a copper (Cu) mesh, a nickel (Ni) foam, and / or carbon paper. For example, the anode current collector 310 can include a stainless steel mesh with carbon nanoparticles deposited thereon. In another example, the anode current collector 310 can be a conductive porous material.

[0056] The anode 312 extracts metal ions from the electrolyte 314 during charging and releases metal ions to the electrolyte 314 during discharging. The anode 312 can be any anode material. For example, the anode 312 can be formed from, but not limited to, lithium, magnesium, sodium, or any possible combination thereof. In some embodiments, the anode 312 consists essentially of elemental lithium, magnesium, or sodium, or lithium, magnesium, or sodium alloyed with one or more additional elements. In one embodiment, the anode 312 is lithium metal.

[0057] The electrolyte 314 includes at least one solvent and at least one halogen-containing compound that acts as an active cathode conversion material. In some embodiments, at least one solvent of the electrolyte 314 can be selected from the group consisting of, but not limited to, carbonate compounds, heterocyclic compounds, ethers, esters, cyclic ethers, cyclic esters, nitriles, and mixtures and combinations thereof. In some embodiments, at least one solvent of the electrolyte 314 can further be selected from, for example, non-aqueous organic solvents such as ethers, glymes, carbonates, nitriles, amides, amines, organic sulfur solvents, organic phosphoric acid solvents, organic silicon solvents, fluorinated solvents, adiponitrile (ADN), propylene carbonate (PC), dioxolane, dimethoxyethane (DME), and mixtures and combinations thereof. In one embodiment, the electrolyte 314 includes a solvent containing 1,3-dioxolane and 1,2-dimethoxyethane in equal amounts. In one embodiment, the electrolyte 314 further includes a lithium salt such as lithium bis(trifluoromethanesulfonyl)imide or LiTFSI.

[0058] At least one halogen-containing compound of the electrolyte 314 functions as an active cathode conversion material. For example, the halogen-containing compound of the electrolyte 314 can receive, accumulate, and release metal ions due to the halogen redox reaction during charging and discharging of the battery 300. In this way, the battery 300 can include a cathode having only a cathode intercalation material instead of a dedicated cathode conversion material. It should be recognized that by having an electrolyte containing a halogen-containing compound that acts as an active cathode conversion material, the battery 300 can be made less expensive and lighter, and can have a higher energy density, a higher power density, or a combination thereof. For example, the high power density of the electrolyte 314 containing a halogen-containing compound that functions as an active cathode conversion material enables the battery 300 to have a higher energy density than other batteries that do not have an electrolyte containing a halogen-containing compound that functions as an active cathode conversion material, and can enable significantly faster charging.

[0059] In some embodiments, the halogen-containing compound of the electrolyte 314 that acts as an active cathode conversion material is molecular halogen. For example, the molecular halogen can be selected from, but is not limited to, F2, Cl2, Br2, and I2. In some embodiments, the halogen-containing compound of the electrolyte 314 that acts as an active cathode conversion material is a metal halide salt (for example, represented as MX with M as the metal element and X as the halogen element). In one embodiment, the metal halide can be dissolved in a solvent and dissociated into respective metal ions and respective halide ions. In one embodiment, the metal ions can be selected from, but are not limited to, + Li 3+ Al 2+ Mg + or Na - at least one of (for example, M can be Li, Al, Mg, or Na), and the halide ions can be selected from, but are not limited to, - I- or F - and may contain ions selected from at least one of (e.g., X can be I, Br, Cl, or F). In other embodiments, the halogen-containing compound of the electrolyte 314 that acts as an active cathode conversion material is an organic halogen salt (e.g., AX represented by using A as an organic species with a positive charge and X as a halogen element with a negative charge). In one embodiment, the organic halogen salt can be dissolved in a solvent and dissociated into respective organic cations and respective halide anions. In one embodiment, the organic cation can be selected from at least one of, but not limited to, ammonia, alkylammonium, imidazolium, or pyrrolidinium, and the halide anion can be, but not limited to, I - Br - Cl - or F - and may contain ions selected from at least one of (e.g., X can be I, Br, Cl, or F).

[0060] In some embodiments, electrolyte 314 further includes one or more oxidizing gases. In certain embodiments, electrolyte 314 can be placed in the presence of an oxidizing gas, and the expression "including an oxidizing gas" is intended to include such a configuration. In certain embodiments, one or more oxidizing gases can be dissolved in a solvent including at least one salt of electrolyte 314 and at least one lithium-containing compound. In certain embodiments, the oxidizing gas can include, but is not limited to, at least one of air, oxygen, nitrogen oxide, nitrogen dioxide, or mixtures and combinations thereof. The oxidizing gas can assist in inducing the redox reaction of battery 300 as described above and in achieving a highly reversible redox reaction, contributing to enhancing the electrochemical performance of battery 300. It should be noted that the oxidizing gas can assist in inducing that kind of redox reaction, but the oxidizing gas is not consumed or released during the use of battery 300 (i.e., the oxidizing gas does not participate in the redox reaction of battery 300).

[0061] Separator 316 forces the flow of electrons through the external electrical circuit to which battery 300 is connected, so that electrons do not move through battery 300 (e.g., through electrolyte 314 of battery 300), but nevertheless allows metal ions to flow through battery 300 during charging and discharging. In various embodiments, separator 316 can be subjected to coating with electrolyte 314, immersion in electrolyte 314, placement within electrolyte 314, or enclosure / solution immersion by electrolyte 314. In certain embodiments, separator 316 includes a non-conductive material to prevent the movement of electrons through battery 300 and instead allows electrons to move through the external circuit. For example, separator 316 can include glass, fibrous non-woven fabric, polymer film, or rubber.

[0062] The cathode 318 includes a lithium-ion intercalation host. In some embodiments, the lithium-ion intercalation host is a metal oxide or a metal phosphate compound. For example, the lithium-ion intercalation host of the cathode 318 can be, but is not limited to, lithium cobalt oxide (LCO) (e.g., LiCoO2), nickel cobalt aluminum (NCA) (e.g., LiNi x Co y Al z O2, LiNi 0.8 Co 0.15 Al 0.05 O2), lithium ion manganese oxide (LMO) (e.g., LiMn2O4), lithium nickel manganese cobalt oxide (NMC) (e.g., LiNiMnCoO2), nickel cobalt manganese oxide (NCM) (e.g., LiNi x Co y Mn z O2, LiNi 0.33 Co 0.33 Mn 0.33 O2), lithium iron phosphate (LFP, e.g., LiFePO4), mixtures and combinations thereof.

[0063] In some embodiments, the cathode 318 further includes a halogen-containing compound that functions as an active cathode conversion material in addition to the lithium-ion intercalation host. In some embodiments, a portion of the lithium-ion intercalation host of the cathode 318 (e.g., nickel or cobalt when the intercalation host is NMC, or cobalt when the intercalation host is LCO) is replaced with a halogen-containing compound that functions as an active cathode conversion material. In other embodiments, a halogen-containing compound that functions as an active cathode material is added to the cathode 318 without replacing a portion of the lithium-ion intercalation host of the cathode 318.

[0064] In one embodiment, the halogen-containing compound of the cathode 318 that functions as an active cathode conversion material is the same as the halogen-containing compound of the electrolyte 314 that also functions as an active cathode conversion material. In one embodiment, the halogen-containing compound included in the cathode 318 that functions as a cathode conversion material is different from the halogen-containing compound included in the electrolyte 314 that also functions as an active cathode conversion material. It should be recognized that by including an active cathode conversion material in both the electrolyte 314 and the cathode 318, a hybrid energy storage device with increased energy density is achieved.

[0065] In one embodiment, the lithium-ion intercalation host of the cathode 318 is a metal oxide or a metal phosphate compound. For example, the lithium-ion intercalation host of the cathode 318 can be, but is not limited to, lithium cobalt oxide (LCO) (e.g., LiCoO2), nickel cobalt aluminum (NCA) (e.g., LiNi x Co y Al z O2, LiNi 0.8 Co 0.15 Al 0.05 O2), lithium ion manganese oxide (LMO) (e.g., LiMn2O4), lithium nickel manganese cobalt oxide (NMC) (e.g., LiNiMnCoO2), nickel cobalt manganese oxide (NCM) (e.g., LiNi x Co y Mn z O2, LiNi 0.33 Co 0.33 Mn 0.33 O2), lithium iron phosphate (LFP, e.g., LiFePO4), and can be selected from mixtures and combinations thereof.

[0066] The cathode 318 is in electrochemical and / or physical contact with the cathode current collector 320. In some embodiments, the cathode 318 of the battery 300 is in a viscous or slurry state. In other embodiments, the cathode 318 of the battery 300 is placed in a solid phase. In embodiments where the cathode 318 is left in a solid phase, the density of the cathode does not necessarily have to be greater than the density of the cathode current collector 320. In certain embodiments, the cathode 318 is initially formed in a viscous or slurry state, coated on at least the bottom surface of the cathode current collector 320, and cured to form the final solid cathode.

[0067] The cathode current collector 320 can include a material with appropriate electrical conductivity that collects electrons generated by the redox reaction during discharge of the battery and provides a conductive path to an external circuit to which the battery 300 is connected. Similarly, during recharging of the battery 300, the cathode current collector 320 provides an electrical path between an external voltage source and the electrolyte 314 that supplies a voltage for another redox reaction to charge the battery 300. The cathode current collector 320 can be formed from any material that achieves stability or passivation at the respective electrochemical potential of the cathode 318. In certain embodiments, the cathode current collector 320 can include a metal fiber woven or non-woven fabric, a metal foam, a metal foil, or a carbon fiber woven or non-woven fabric. In certain embodiments, the cathode current collector 320 can include, additionally or alternatively, a stainless steel mesh, an aluminum (Al) mesh, a nickel (Ni) foam, and / or carbon paper. For example, the cathode current collector 320 can include a stainless steel mesh with aluminum nanoparticles deposited thereon. In another example, the cathode current collector 320 can be a conductive porous material.

[0068] In some embodiments, the battery 300 has a closed volume. For example, the anode current collector 310, anode 312, electrolyte 314, separator 316, cathode 318, and cathode current collector 320 are housed within an encapsulated cell or other enclosure. In this way, one or more oxidation additives within the battery 300 remain confined within the battery 300. In other embodiments, the battery 300 has a substantially closed volume. For example, the anode current collector 310, anode 312, electrolyte 314, separator 316, cathode 318, and cathode current collector 320 are housed within a substantially encapsulated cell or other enclosure. In this way, removal and / or addition of one or more oxidation additives within the battery 300 from / to the battery 300 is possible.

[0069] FIG. 4 is a conceptual diagram illustrating the battery 300 of FIG. 3 within an encapsulated cell system 400. The encapsulated cell system 400 can include the cell that houses the battery 300 during operation of the battery 300, the cell used in the manufacture of the battery 300, or both. For example, the encapsulated cell system 400 can include a cell available from Swagelok of Solon, Ohio, under the trade designation "SWAGELOK" and can be used in the manufacture of the battery 300. In one embodiment, the encapsulated cell system 400 can include an inlet tube 410 and / or an outlet tube 420. The inlet tube 410 and the outlet tube 420 can be used for introducing and discharging into the encapsulated cell system 400 an oxidation additive including, but not limited to, air, oxygen, nitrogen oxides, nitrogen dioxide, and mixtures and combinations thereof.

[0070] First Procedure Preparation of a Secondary Energy Storage Device with a 'Solid Phase' Hybrid Cathode

[0071] First, a cathode was prepared by forming a slurry comprising a halogen cathode conversion material (e.g., I2) or a metal halide cathode conversion material (e.g., LiI), a lithium-based intercalation cathode material (e.g., LFP), a conductive additive, and a binder. Subsequently, the slurry was coated onto a current collector and dried to create a finished cathode.

[0072] An electrolyte was prepared by dissolving a lithium salt (e.g., LiTFSI) in one or more aprotic organic solvents (e.g., a 1:1 1,3-dioxolane / 1,2-dimethoxyethane mixture) to achieve a desired electrolyte concentration.

[0073] Second procedure Preparation of a secondary energy storage device with a 'dissolved phase' hybrid cathode

[0074] A cathode was prepared by forming a slurry comprising an intercalation cathode material (e.g., LFP), a conductive additive, and a binder. Subsequently, the slurry was coated onto a current collector and dried to create a finished cathode.

[0075] A cathode / electrolyte solution was prepared by dissolving a metal halide salt (e.g., LiI) or a halogen (I2) in one or more aprotic organic solvents (e.g., a 1:1 1,3-dioxolane / 1,2-dimethoxyethane mixture) to achieve a desired cathode / electrolyte concentration.

[0076] Example 1 Formation of a secondary energy storage device with a'solid phase' hybrid cathode

[0077] A secondary energy storage device with a "solid phase" hybrid cathode was formed by placing a wave spring inside the negative side of a 2032 type coin battery. Subsequently, a lithium foil piece (anode) was placed on top of a 0.5 mm stainless steel spacer, and it was then placed on top of the wave spring. A small amount of electrolyte prepared according to the first procedure was deposited on the lithium metal anode, followed by placing a polymer separator (e.g., Celgard 2325) on top of them. Then, another small amount of electrolyte prepared according to the first procedure was placed on top of the polymer separator, followed by placing a hybrid cathode prepared according to the first procedure on top of it. Finally, the coin cell was sealed.

[0078] Example 2 Formation of a secondary energy storage device with a "dissolved phase" hybrid cathode

[0079] A secondary energy storage device with a "dissolved phase" hybrid cathode was formed by placing a wave spring inside the negative side of a 2032 type coin battery. Subsequently, a lithium foil piece (anode) was placed on top of a 0.5 mm stainless steel spacer, and it was then placed on top of the wave spring. A small amount of cathode / electrolyte solution prepared according to the second procedure was deposited on the lithium metal anode, followed by placing a polymer separator (e.g., Celgard 2325) on top of them. Then, another small amount of cathode / electrolyte solution prepared according to the second procedure was placed on top of the polymer separator, followed by placing a hybrid cathode prepared according to the second procedure on top of it. Finally, the cell was sealed.

[0080] Comparative Example 1 Areal capacity of a cell with a "dissolved phase" cathode containing only a single active conversion material (LiI)

[0081] Figure 5 is a plot of the areal capacity of a cell with a 'dissolved phase' LiI cathode. More specifically, Figure 5 illustrates the specific capacity normalized by the cathode area of a cell formed from a lithium metal anode, porous carbon on a carbon fiber cloth cathode, and 100 μL of an electrolyte containing 0.4 mM LiNO3 and 1 mM LiI in 500 μL of 1,3-dioxolane and 500 μL of 1,2-dimethoxyethane.

[0082] Comparative Example 2 Areal capacity of a cell with a cathode containing only a single active intercalation material (LiFePO4)

[0083] Figure 6 is a plot showing the areal capacity of a cell with a LiFePO4 cathode. More specifically, Figure 6 illustrates the specific capacity normalized by the cathode area of a cell formed from a lithium metal anode, porous carbon on a carbon fiber cloth cathode and lithium iron phosphate, and 100 μL of an electrolyte containing 0.4 mM LiNO3 and 1 mM LiPF6 in 500 μL of 1,3-dioxolane and 500 μL of 1,2-dimethoxyethane.

[0084] Example 1 Areal capacity of a first cell with a hybrid dissolved phase LiI / solid phase LiFePO4 cathode

[0085] Figure 7 is a plot of the areal capacity of a cell with a hybrid dissolved state LiI / solid phase LiFePO4 cathode. More specifically, Figure 7 illustrates the specific capacity normalized by the cathode area of a cell formed from a lithium metal anode, porous carbon on a carbon fiber cloth cathode and lithium iron phosphate, and 100 μL of an electrolyte containing 0.4 mM LiNO3 and 1 mM LiI in 500 μL of 1,3-dioxolane and 500 μL of 1,2-dimethoxyethane.

[0086] Example 2 Areal capacity of a second cell with a hybrid dissolved phase LiI / solid phase LiFePO4 cathode

[0087] Figure 8 is a plot of the areal capacity of a cell with a hybrid dissolved-state LiI / solid-phase LiFePO4 cathode. More specifically, Figure 8 shows the specific capacity normalized by the cathode area of a cell formed from a lithium metal anode, porous carbon and lithium iron phosphate on a carbon fiber cloth cathode, and 100 μL of electrolyte containing 0.4 mM LiNO3 and 5 mM LiI in 500 μL of 1,3-dioxolane and 500 μL of 1,2-dimethoxyethane.

[0088] Cycle performance example 1 The first cell formed from a hybrid dissolved-phase LiI / solid-phase LiFePO4 cathode

[0089] Figure 9 illustrates the cycle performance of a cell formed from a hybrid dissolved-phase LiI / solid-phase LiFePO4 cathode. More specifically, Figure 9 shows the cycle performance of a cell containing a lithium metal anode, porous carbon and lithium iron phosphate on a carbon fiber cloth cathode, and 100 μL of electrolyte containing 0.4 mM LiNO3 and 1 mM LiI in 500 μL of 1,3-dioxolane and 500 μL of 1,2-dimethoxyethane. Galvanostat cycling was performed in the voltage range of 2.7 - 3 V such that the electrochemistry of iodine, rather than that of LFP, contributes to the total capacity of the cell.

[0090] Cycle performance example 2 The second cell formed from a hybrid dissolved-phase LiI / solid-phase LiFePO4 cathode

[0091] Figure 10 illustrates the cycle performance of a cell formed from a hybrid dissolved-phase LiI / solid-phase LiFePO4 cathode. More specifically, Figure 10 illustrates the cycle performance of a cell comprising a lithium metal anode, porous carbon and lithium iron phosphate on a carbon fiber cloth cathode, and an electrolyte of 100 μL containing 0.4 mM LiNO3 and 1 mM LiI by 500 μL of 1,3-dioxolane and 500 μL of 1,2-dimethoxyethane. Galvanostat cycling was performed within a voltage range of 3 - 3.6 V so that the electrochemistry of LFP, rather than that of iodine, contributes to the total capacity of the cell.

[0092] Cycle performance example 3 The third cell formed from a hybrid dissolved-phase LiI / solid-phase LiFePO4 cathode

[0093] Figure 11 illustrates the cycle performance of a cell formed from a hybrid dissolved-phase LiI / solid-phase LiFePO4 cathode. More specifically, Figure 11 illustrates the cycle performance of a cell comprising a lithium metal anode, porous carbon and lithium iron phosphate on a carbon fiber cloth cathode, and an electrolyte of 100 μL containing 0.4 mM LiNO3 and 1 mM LiI by 500 μL of 1,3-dioxolane and 500 μL of 1,2-dimethoxyethane. Galvanostat cycling was performed within a voltage range of 2.7 - 3.6 V so that the electrochemistry of both iodine and LFP contributes to the total capacity of the cell.

Description of symbols

[0094] 100 Solid-phase hybrid battery, battery 110 Anode current collector 112 Anode 114 Electrolyte 116 Separator 118 Cathode 120 Cathode current collector 200 Encapsulated cell system 210 Introduction tube 220 Discharge tube 300 Dissolved-phase hybrid battery, battery 310 Anode current collector 312 Anode 314 Electrolyte 316 Separator 318 Cathode 320 Cathode current collector 400 Encapsulated cell system 410 Inlet pipe 420 Outlet pipe

Claims

1. A rechargeable battery comprising: an anode; a cathode comprising a lithium-ion intercalation host; an electrolyte comprising a solvent and a first halogen-containing compound that functions as an active cathode conversion material, the electrolyte being in contact with the anode and the cathode; A rechargeable battery.

2. The rechargeable battery according to claim 1, wherein the cathode further comprises a second halogen-containing compound that functions as an active cathode conversion material.

3. The rechargeable battery according to claim 2, wherein the first halogen-containing compound that functions as an active cathode conversion material contained in the electrolyte is the same as the second halogen-containing compound that functions as an active cathode conversion material contained in the cathode.

4. The rechargeable battery according to claim 2, wherein the first halogen-containing compound that functions as an active cathode conversion material contained in the electrolyte is different from the second halogen-containing compound that functions as an active cathode conversion material contained in the cathode.

5. The rechargeable battery according to claim 1, wherein the halogen-containing compound that functions as an active cathode conversion material contained in the electrolyte is a metal halide.

6. The metal halide dissociates into respective halide ions and respective metal ions in the solvent, and the halide ions are I － , Br － , Cl － , or F － , and the metal ions include at least one of Li ＋ , Al ３＋ , Mg ２＋ , or Na ＋ . The rechargeable battery according to claim 4.

7. The rechargeable battery according to claim 1, wherein the lithium-ion intercalation host is selected from the group consisting of lithium cobalt oxide, nickel cobalt aluminum, lithium ion manganese oxide, lithium nickel manganese cobalt oxide, nickel cobalt manganese oxide, lithium iron phosphate, and mixtures and combinations thereof.

8. The rechargeable battery according to claim 1, wherein the solvent of the electrolyte is selected from the group consisting of carbonate compounds, heterocyclic compounds, ethers, esters, cyclic ethers, cyclic esters, nitriles, and mixtures and combinations thereof.

9. The rechargeable battery according to claim 1, further comprising one or more oxidizing gases selected from the group consisting of air, oxygen, nitrogen oxide, nitrogen dioxide, and mixtures and combinations thereof.

10. A rechargeable battery comprising: an anode; a cathode comprising a halogen-containing compound that functions as an active cathode conversion material and a lithium-ion intercalation host; An electrolyte comprising a solvent and a lithium-containing compound, the electrolyte being in contact with the anode and the cathode, A rechargeable battery comprising the same.

11. The rechargeable battery according to claim 10, wherein the halogen-containing compound functioning as the active cathode conversion material contained in the cathode is a halogen or a metal halide.

12. The metal halide contains respective halide ions and respective metal ions, and the halide ions include at least one of I － , Br － , Cl － , or F － . The metal ions include at least one of Li ＋ , Al ３＋ , Mg ２＋ , or Na ＋ . The rechargeable battery according to claim 11.

13. The rechargeable battery according to claim 10, wherein the lithium-containing compound contained in the electrolyte is a lithium salt.

14. The rechargeable battery according to claim 10, wherein the lithium-ion intercalation host is selected from the group consisting of lithium cobaltate, nickel cobalt aluminum, lithium ion manganese oxide, lithium nickel manganese cobalt oxide, nickel cobalt manganese oxide, lithium iron phosphate, and mixtures and combinations thereof.

15. The rechargeable battery according to claim 10, wherein the solvent of the electrolyte is selected from the group consisting of carbonate compounds, heterocyclic compounds, ethers, esters, cyclic ethers, cyclic esters, nitriles, and mixtures and combinations thereof.

16. The rechargeable battery according to claim 10, further comprising one or more oxidizing gases selected from the group consisting of air, oxygen, nitrogen oxide, nitrogen dioxide, and mixtures and combinations thereof.

17. A method of forming a rechargeable battery, Coating a slurry containing a lithium-containing intercalation material on a cathode current collector; Dissolving at least one of a metal halide or a halogen in a solvent to form an electrolyte; Stacking an anode, a separator, and the cathode current collector to form the rechargeable battery, The rechargeable battery comprising: The anode; The electrolyte containing at least one of the metal halide or the halogen functioning as an active cathode conversion material; The separator; The cathode current collector coated with the slurry; A method of forming a rechargeable battery.

18. Further comprising adding a second halogen or metal halide to the cathode, wherein the second halogen or metal halide also functions as an active cathode conversion material, the method according to claim 17.

19. The method according to claim 18, wherein the second halogen or metal halide added to the cathode is the same as the halogen or metal halide contained in the electrolyte.

20. The method according to claim 19, wherein the second halogen or metal halide added to the cathode is different from the halogen or metal halide contained in the electrolyte.

21. Further comprising replacing a portion of the lithium-ion intercalation material with a second metal halide or halogen, wherein the second metal halide or halogen also functions as an active cathode conversion material, the method according to claim 17.

22. The method according to claim 21, wherein the second metal halide or halogen replacing the portion of the lithium-ion intercalation material is the same as the halogen or metal halide contained in the electrolyte.

23. The method according to claim 21, wherein the second metal halide or halogen replacing the portion of the lithium-ion intercalation material is different from the halogen or metal halide contained in the electrolyte.

24. A method of forming a rechargeable battery, comprising: coating a slurry comprising at least one of a halogen or a metal halide and a lithium-containing cathode intercalation material on a cathode current collector; dissolving a lithium salt in a solvent to form an electrolyte; stacking an anode, a separator, and the cathode current collector to form the rechargeable battery; wherein the rechargeable battery comprises: the anode; the electrolyte; the separator; the cathode current collector coated with the slurry; wherein at least one of the halogen or the metal halide in the slurry functions as an active cathode conversion material. A method of forming a rechargeable battery.

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