ABSTRACT
Abstract
The present disclosure provides a solid-state battery including at least one current collector that is in communication with one or more switches configured to move between open and closed positions, where the open position corresponds to a first operational state of the solid-state battery and the closed position corresponds to a second operational state of the solid-state battery; one or more electrodes disposed adjacent to the one or more current collectors; and one or more electrothermal material foils including a resistor material that is in electrical communication with that at least one current collector, where in the first operational state electrons may flow through the one or more electrothermal material foils during cycling of the solid-state battery so as to initiate a heating mode, and in the second operational state electrons may flow through the current collector during cycling of the solid-state battery so as to initiate a non-heating mode.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit and priority of Chinese Application No. 202110295505.5, filed Mar. 19, 2021. The entire disclosure of the above application is incorporated herein by reference.
INTRODUCTION
This section provides background information related to the present disclosure which is not necessarily prior art.
Electrochemical energy storage devices, such as lithium-ion batteries, can be used in a variety of products, including automotive products such as start-stop systems (e.g., 12V start-stop systems), battery-assisted systems (âuBASâ), Hybrid Electric Vehicles (âHEVsâ), and Electric Vehicles (âEVsâ). Typical lithium-ion batteries include two electrodes and an electrolyte component and/or separator. One of the two electrodes can serve as a positive electrode or cathode, and the other electrode can serve as a negative electrode or anode. Lithium-ion batteries may also include various terminal and packaging materials. Rechargeable lithium-ion batteries operate by reversibly passing lithium ions back and forth between the negative electrode and the positive electrode. For example, lithium ions may move from the positive electrode to the negative electrode during charging of the battery and in the opposite direction when discharging the battery. A separator and/or electrolyte may be disposed between the negative and positive electrodes. The electrolyte is suitable for conducting lithium ions between the electrodes and, like the two electrodes, may be in a solid form, a liquid form, or a solid-liquid hybrid form. In the instances of solid-state batteries, which include a solid-state electrolyte layer disposed between solid-state electrodes, the solid-state electrolyte physically separates the solid-state electrodes so that a distinct separator is not required.
Solid-state batteries have advantages over batteries that include a separator and a liquid electrolyte. These advantages can include a lower self-discharge, simpler thermal management, a reduced need for packaging, and the ability to operate within a wider temperature window. For example, solid-state electrolytes are generally non-volatile and non-flammable allowing cells to be cycled under harsher conditions without experiencing diminished potential or thermal runaway, which can potentially occur with the use of liquid electrolytes. However, solid-state batteries generally experience comparatively low power capabilities. For example, such low power capabilities may be a result of interfacial resistance caused by limited contact, or void spaces, between the solid-state active particles and/or the solid-state electrolyte particles. Accordingly, it would be desirable to develop high-performance solid-state battery designs, materials, and methods that improve power capabilities, as well as energy density.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
The present disclosure relates to solid-state batteries (SSBs), for example bipolar solid-state batteries, that include one or more electrothermal material foils and a metal foam material, for example as a current collector. Each bipolar solid-state battery includes a plurality of solid-state electroactive material particles and a plurality of solid-state electrolyte particles embedded within pores of a metal foam and one or more current collector foils disposed on or adjacent to one or more surfaces of the metal foam material. The one or more electrothermal material foils may be configured to heat the solid-state battery during cycling.
In various aspects, the present disclosure provides a solid-state battery that is configured to cycle lithium ions. The solid-state battery may include one or more current collectors, where at least one of the one or more current collectors may be in communication with one or more switches that are configured to move between an open position and a closed position, and where the open position corresponds to a first operational state of the solid-state battery and the closed position corresponds to a second operational state of the solid-state battery; one or more electrodes disposed adjacent to the one or more current collectors, where each electrode may have a thickness greater than or equal to about 100 μm to less than or equal to about 3,000 μm and may include a plurality of solid-state electroactive material particles; and one or more electrothermal material foils including a resistor material that is in electrical communication with at least one of the one or more current collectors, where in the first operational state electrons may flow through the one or more electrothermal material foils during cycling of the solid-state battery so as to initiate a heating mode, and in the second operational state electrons may flow through the one or more current collectors during cycling of the solid-state battery so as to initiate a non-heating mode.
In one aspect, each of the one or more electrothermal material foils may have a thickness greater than or equal to about 5 μm to less than or equal to about 200 μm.
In one aspect, the resistor material may be selected from the group consisting of: nickel, stainless steel, copper, constantan, chromium, aluminum, iron, titanium, graphite, and alloys and combinations thereof.
In one aspect, at least one of the one or more electrothermal material foils may be patterned. The pattern may include a plurality of void areas.
In one aspect, the plurality of solid-state electroactive material particles may be disposed on or embedded in a porous material.
In one aspect, the porous material may have a porosity greater than or equal to about 80 vol. % to less than or equal to about 95 vol. %.
In one aspect, the porous material may have an average pore size greater than or equal to about 2 μm to less than or equal to about 1000 μm.
In one aspect, the porous material may have a thickness greater than or equal to about 100 μm to less than or equal to about 4000 μm.
In one aspect, the porous material may be a metal foam. The metal foam may be selected from an aluminum (Al) foam, a nickel (Ni) foam, a copper (Cu) foam, a nickel-chromium (NiâCr) foam, a nickel-tin (NiâSn) foam, and a titanium (Ti) foam.
In one aspect, the porous material may be one of a carbon nanofiber three-dimensional foam, a graphene foam, a carbon cloth, a carbon fiber-embedded carbon nanotubes, and a graphene-nickel foam.
In one aspect, the one or more electrodes may include a first electrode and a second electrode. The first electrode may include a first plurality of solid-state electroactive material particles, and the second electrode may include a second plurality of solid-state electroactive material particles.
In one aspect, the one or more current collectors may include a first current collector. The first plurality of solid-state electroactive material particles may be disposed adjacent to a first surface of the first current collector. The second plurality of solid-state electroactive material particles may be disposed adjacent to a second surface of the first current collector that opposes the first surface.
In one aspect, the first current collector may include a first film and a second film. The second film may be parallel with the first film. The first film may define the first surface of the first current collector, and the second film may define the second surface of the first current collector.
In one aspect, the first film may have a thickness less than or equal to about 10 μm, and the second film may have a thickness less than or equal to about 10 μm.
In one aspect, the first electrode may further include a plurality of solid-state electrolyte particles. The plurality of solid-state electrolyte particles may be mixed with the first plurality of solid-state electroactive material particles and also disposed on the porous material.
In one aspect, the first plurality of solid-state electroactive material particles may be disposed on a first section of the porous material, and the second plurality of solid-state electroactive material particles may be disposed on a second section of the porous material.
In one aspect, the plurality of solid-state electrolyte particles mixed with the first plurality of solid-state electroactive material particles may be a first plurality of solid-state electrolyte particles, and the second electrode may further include a second plurality of solid-state electrolyte particles. The second plurality of solid-state electrolyte particles may be mixed with the second plurality of solid-state electroactive material particles and also disposed on the porous material.
In one aspect, the first current collector may be a film disposed on a third portion of the porous material that is formed between the first and second portions of the porous material.
In one aspect, the one or more current collectors may include a first current collector and a second current collector. The second current collector may be parallel with the first current collector. The one or more electrodes may include a first electrode and a second electrode. The first electrode may include a first plurality of solid-state electroactive material particles disposed adjacent to the first current collector. The second electrode may include a second plurality of solid-state electroactive material particles disposed adjacent to the second current collector. The solid-state battery may further include a solid-state electrolyte layer that is disposed between the first electrode and the second electrode. The solid-state electrolyte layer may include a plurality of solid-state electrolyte particles.
In one aspect, the solid-state electrolyte layer may have a thickness greater than or equal to about 5 μm to less than or equal to about 100 μm.
In one aspect, the solid-state electrolyte layer may include a first sublayer and a second sublayer. The first sublayer may include a first plurality of solid-state electrolyte particles. The second sublayer may include a second plurality of solid-state electrolyte particles. The first and second pluralities of solid-state electrolyte particles may be the same or different.
In various aspects, the present disclosure provides a solid-state battery that is configured to cycle lithium ion. The solid-state battery may include a first current collector; a first electrode having a thickness greater than or equal to about 100 μm to less than or equal to about 3,000 μm disposed adjacent to the first current collector; a second current collector parallel with the first current collector, where at least one of the first and second current collectors is in communication with one or more switches that are configured to move the solid-state battery between an open position and a closed position, and where the open position corresponds to a first operational state of the solid-state battery and the closed position corresponds to a second operational state of the solid-state battery; a second electrode having a thickness greater than or equal to about 100 μm to less than or equal to about 3,000 μm disposed adjacent to the second current collector; a solid-state electrolyte layer disposed between the first electrode and the second electrode; and one or more electrothermal material foils having a thickness greater than or equal to about 5 μm to less than or equal to about 200 μm and including a resistor material in electrical communication with at least one of the first and second current collectors, where in the first operational state electrons may flow through the one or more electrothermal material foils during cycling of the solid-state battery so as to initiate a heating mode, and in the second operational state electrons may flow through at least one of the first and second current collectors during cycling of the solid-state battery so as to initiate a non-heating mode. The first electrode may include a first plurality of solid-state electroactive material particles disposed on or embedded in a first porous material. The second electrode may include a second plurality of solid-state electroactive material particles disposed on or embedded in a second porous material.
In one aspect, the first and second porous materials may each have a porosity greater than or equal to about 80 vol. % to less than or equal to about 95 vol. %.
In one aspect, the first and second porous materials may each have an average pore size of greater than or equal to about 2 μm to less than or equal to about 1000 μm.
In one aspect, the first and second porous materials may each have a thickness greater than or equal to about 100 μm to less than or equal to about 4000 μm.
In one aspect, the resistor material may be selected from the group consisting of: nickel, stainless steel, copper, constantan, chromium, aluminum, iron, titanium, graphite, and alloys and combinations thereof.
In one aspect, at least one of the one or more electrothermal material foils may be patterned. The pattern may include a plurality of void areas.
In one aspect, at least one of the first and second current collectors may include a first film and a second film. The second film may be parallel with the first film. The first and second films may each have a thickness less than about 10 μm.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is an illustration of an example solid-state battery including a metal foam in accordance with various aspects of the present disclosure;
FIG. 2 is an electron microscope image of an example metal foam, such as included in the example solid-state battery illustrated in FIG. 1 , in accordance with various aspects of the present disclosure;
FIG. 3 is an illustration of an example solid-state battery including a metal foam and an electrothermal material foil in accordance with various aspects of the present disclosure;
FIG. 4 includes illustrations of example patterns for example electrothermal material foils, such as included in the example solid-state battery illustrated in FIG. 3 , in accordance with various aspects of the present disclosure;
FIG. 5 is an illustration of an example electrothermal material foil, such as included in the example solid-state battery illustrated in FIG. 3 , having an insulating coating in accordance with various aspects of the present disclosure;
FIG. 6 is an example method of activating an electrothermal material foil, such as included in the example solid-state battery illustrated in FIG. 3 , in accordance with various aspects of the
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit and priority of Chinese Application No. 202110295505.5, filed Mar. 19, 2021. The entire disclosure of the above application is incorporated herein by reference.
INTRODUCTION
This section provides background information related to the present disclosure which is not necessarily prior art.
Electrochemical energy storage devices, such as lithium-ion batteries, can be used in a variety of products, including automotive products such as start-stop systems (e.g., 12V start-stop systems), battery-assisted systems (âuBASâ), Hybrid Electric Vehicles (âHEVsâ), and Electric Vehicles (âEVsâ). Typical lithium-ion batteries include two electrodes and an electrolyte component and/or separator. One of the two electrodes can serve as a positive electrode or cathode, and the other electrode can serve as a negative electrode or anode. Lithium-ion batteries may also include various terminal and packaging materials. Rechargeable lithium-ion batteries operate by reversibly passing lithium ions back and forth between the negative electrode and the positive electrode. For example, lithium ions may move from the positive electrode to the negative electrode during charging of the battery and in the opposite direction when discharging the battery. A separator and/or electrolyte may be disposed between the negative and positive electrodes. The electrolyte is suitable for conducting lithium ions between the electrodes and, like the two electrodes, may be in a solid form, a liquid form, or a solid-liquid hybrid form. In the instances of solid-state batteries, which include a solid-state electrolyte layer disposed between solid-state electrodes, the solid-state electrolyte physically separates the solid-state electrodes so that a distinct separator is not required.
Solid-state batteries have advantages over batteries that include a separator and a liquid electrolyte. These advantages can include a lower self-discharge, simpler thermal management, a reduced need for packaging, and the ability to operate within a wider temperature window. For example, solid-state electrolytes are generally non-volatile and non-flammable allowing cells to be cycled under harsher conditions without experiencing diminished potential or thermal runaway, which can potentially occur with the use of liquid electrolytes. However, solid-state batteries generally experience comparatively low power capabilities. For example, such low power capabilities may be a result of interfacial resistance caused by limited contact, or void spaces, between the solid-state active particles and/or the solid-state electrolyte particles. Accordingly, it would be desirable to develop high-performance solid-state battery designs, materials, and methods that improve power capabilities, as well as energy density.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
The present disclosure relates to solid-state batteries (SSBs), for example bipolar solid-state batteries, that include one or more electrothermal material foils and a metal foam material, for example as a current collector. Each bipolar solid-state battery includes a plurality of solid-state electroactive material particles and a plurality of solid-state electrolyte particles embedded within pores of a metal foam and one or more current collector foils disposed on or adjacent to one or more surfaces of the metal foam material. The one or more electrothermal material foils may be configured to heat the solid-state battery during cycling.
In various aspects, the present disclosure provides a solid-state battery that is configured to cycle lithium ions. The solid-state battery may include one or more current collectors, where at least one of the one or more current collectors may be in communication with one or more switches that are configured to move between an open position and a closed position, and where the open position corresponds to a first operational state of the solid-state battery and the closed position corresponds to a second operational state of the solid-state battery; one or more electrodes disposed adjacent to the one or more current collectors, where each electrode may have a thickness greater than or equal to about 100 μm to less than or equal to about 3,000 μm and may include a plurality of solid-state electroactive material particles; and one or more electrothermal material foils including a resistor material that is in electrical communication with at least one of the one or more current collectors, where in the first operational state electrons may flow through the one or more electrothermal material foils during cycling of the solid-state battery so as to initiate a heating mode, and in the second operational state electrons may flow through the one or more current collectors during cycling of the solid-state battery so as to initiate a non-heating mode.
In one aspect, each of the one or more electrothermal material foils may have a thickness greater than or equal to about 5 μm to less than or equal to about 200 μm.
In one aspect, the resistor material may be selected from the group consisting of: nickel, stainless steel, copper, constantan, chromium, aluminum, iron, titanium, graphite, and alloys and combinations thereof.
In one aspect, at least one of the one or more electrothermal material foils may be patterned. The pattern may include a plurality of void areas.
In one aspect, the plurality of solid-state electroactive material particles may be disposed on or embedded in a porous material.
In one aspect, the porous material may have a porosity greater than or equal to about 80 vol. % to less than or equal to about 95 vol. %.
In one aspect, the porous material may have an average pore size greater than or equal to about 2 μm to less than or equal to about 1000 μm.
In one aspect, the porous material may have a thickness greater than or equal to about 100 μm to less than or equal to about 4000 μm.
In one aspect, the porous material may be a metal foam. The metal foam may be selected from an aluminum (Al) foam, a nickel (Ni) foam, a copper (Cu) foam, a nickel-chromium (NiâCr) foam, a nickel-tin (NiâSn) foam, and a titanium (Ti) foam.
In one aspect, the porous material may be one of a carbon nanofiber three-dimensional foam, a graphene foam, a carbon cloth, a carbon fiber-embedded carbon nanotubes, and a graphene-nickel foam.
In one aspect, the one or more electrodes may include a first electrode and a second electrode. The first electrode may include a first plurality of solid-state electroactive material particles, and the second electrode may include a second plurality of solid-state electroactive material particles.
In one aspect, the one or more current collectors may include a first current collector. The first plurality of solid-state electroactive material particles may be disposed adjacent to a first surface of the first current collector. The second plurality of solid-state electroactive material particles may be disposed adjacent to a second surface of the first current collector that opposes the first surface.
In one aspect, the first current collector may include a first film and a second film. The second film may be parallel with the first film. The first film may define the first surface of the first current collector, and the second film may define the second surface of the first current collector.
In one aspect, the first film may have a thickness less than or equal to about 10 μm, and the second film may have a thickness less than or equal to about 10 μm.
In one aspect, the first electrode may further include a plurality of solid-state electrolyte particles. The plurality of solid-state electrolyte particles may be mixed with the first plurality of solid-state electroactive material particles and also disposed on the porous material.
In one aspect, the first plurality of solid-state electroactive material particles may be disposed on a first section of the porous material, and the second plurality of solid-state electroactive material particles may be disposed on a second section of the porous material.
In one aspect, the plurality of solid-state electrolyte particles mixed with the first plurality of solid-state electroactive material particles may be a first plurality of solid-state electrolyte particles, and the second electrode may further include a second plurality of solid-state electrolyte particles. The second plurality of solid-state electrolyte particles may be mixed with the second plurality of solid-state electroactive material particles and also disposed on the porous material.
In one aspect, the first current collector may be a film disposed on a third portion of the porous material that is formed between the first and second portions of the porous material.
In one aspect, the one or more current collectors may include a first current collector and a second current collector. The second current collector may be parallel with the first current collector. The one or more electrodes may include a first electrode and a second electrode. The first electrode may include a first plurality of solid-state electroactive material particles disposed adjacent to the first current collector. The second electrode may include a second plurality of solid-state electroactive material particles disposed adjacent to the second current collector. The solid-state battery may further include a solid-state electrolyte layer that is disposed between the first electrode and the second electrode. The solid-state electrolyte layer may include a plurality of solid-state electrolyte particles.
In one aspect, the solid-state electrolyte layer may have a thickness greater than or equal to about 5 μm to less than or equal to about 100 μm.
In one aspect, the solid-state electrolyte layer may include a first sublayer and a second sublayer. The first sublayer may include a first plurality of solid-state electrolyte particles. The second sublayer may include a second plurality of solid-state electrolyte particles. The first and second pluralities of solid-state electrolyte particles may be the same or different.
In various aspects, the present disclosure provides a solid-state battery that is configured to cycle lithium ion. The solid-state battery may include a first current collector; a first electrode having a thickness greater than or equal to about 100 μm to less than or equal to about 3,000 μm disposed adjacent to the first current collector; a second current collector parallel with the first current collector, where at least one of the first and second current collectors is in communication with one or more switches that are configured to move the solid-state battery between an open position and a closed position, and where the open position corresponds to a first operational state of the solid-state battery and the closed position corresponds to a second operational state of the solid-state battery; a second electrode having a thickness greater than or equal to about 100 μm to less than or equal to about 3,000 μm disposed adjacent to the second current collector; a solid-state electrolyte layer disposed between the first electrode and the second electrode; and one or more electrothermal material foils having a thickness greater than or equal to about 5 μm to less than or equal to about 200 μm and including a resistor material in electrical communication with at least one of the first and second current collectors, where in the first operational state electrons may flow through the one or more electrothermal material foils during cycling of the solid-state battery so as to initiate a heating mode, and in the second operational state electrons may flow through at least one of the first and second current collectors during cycling of the solid-state battery so as to initiate a non-heating mode. The first electrode may include a first plurality of solid-state electroactive material particles disposed on or embedded in a first porous material. The second electrode may include a second plurality of solid-state electroactive material particles disposed on or embedded in a second porous material.
In one aspect, the first and second porous materials may each have a porosity greater than or equal to about 80 vol. % to less than or equal to about 95 vol. %.
In one aspect, the first and second porous materials may each have an average pore size of greater than or equal to about 2 μm to less than or equal to about 1000 μm.
In one aspect, the first and second porous materials may each have a thickness greater than or equal to about 100 μm to less than or equal to about 4000 μm.
In one aspect, the resistor material may be selected from the group consisting of: nickel, stainless steel, copper, constantan, chromium, aluminum, iron, titanium, graphite, and alloys and combinations thereof.
In one aspect, at least one of the one or more electrothermal material foils may be patterned. The pattern may include a plurality of void areas.
In one aspect, at least one of the first and second current collectors may include a first film and a second film. The second film may be parallel with the first film. The first and second films may each have a thickness less than about 10 μm.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is an illustration of an example solid-state battery including a metal foam in accordance with various aspects of the present disclosure;
FIG. 2 is an electron microscope image of an example metal foam, such as included in the example solid-state battery illustrated in FIG. 1 , in accordance with various aspects of the present disclosure;
FIG. 3 is an illustration of an example solid-state battery including a metal foam and an electrothermal material foil in accordance with various aspects of the present disclosure;
FIG. 4 includes illustrations of example patterns for example electrothermal material foils, such as included in the example solid-state battery illustrated in FIG. 3 , in accordance with various aspects of the present disclosure;
FIG. 5 is an illustration of an example electrothermal material foil, such as included in the example solid-state battery illustrated in FIG. 3 , having an insulating coating in accordance with various aspects of the present disclosure;
FIG. 6 is an example method of activating an electrothermal material foil, such as included in the example solid-state battery illustrated in FIG. 3 , in accordance with various aspects of the present disclosure;
FIG. 7 is another example method of activating an electrothermal material foil, such as included in the example solid-state battery illustrated in FIG. 3 , in accordance with various aspects of the present disclosure;
FIG. 8 is an illustration of another example solid-state battery including a metal foam and an electrothermal material foil in accordance with various aspects of the present disclosure;
FIG. 9 includes illustrations of example patterns for example electrothermal material foils, such as included in the example solid-state battery illustrated in FIG. 8 , in accordance with various aspects of the present disclosure;
FIG. 10 is an illustration of another example solid-state battery including a metal foam, an electrothermal material foil, and a dual solid-state electrolyte layer in accordance with various aspects of the present disclosure;
FIG. 11 is an illustration of another example solid-state battery including a metal foam, an electrothermal material foil, and a dual current collector in accordance with various aspects of the present disclosure; and
FIG. 12 is an illustration of another example solid-state battery including a partial metal foam and an electrothermal material foil in accordance with various aspects of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific compositions, components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms âa,â âan,â and âtheâ may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms âcomprises,â âcomprising,â âincluding,â and âhaving,â are inclusive and therefore specify the presence of stated features, elements, compositions, steps, integers, operations, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Although the open-ended term âcomprising,â is to be understood as a non-restrictive term used to describe and claim various embodiments set forth herein, in certain aspects, the term may alternatively be understood to instead be a more limiting and restrictive term, such as âconsisting ofâ or âconsisting essentially of.â Thus, for any given embodiment reciting compositions, materials, components, elements, features, integers, operations, and/or process steps, the present disclosure also specifically includes embodiments consisting of, or consisting essentially of, such recited compositions, materials, components, elements, features, integers, operations, and/or process steps. In the case of âconsisting of,â the alternative embodiment excludes any additional compositions, materials, components, elements, features, integers, operations, and/or process steps, while in the case of âconsisting essentially of,â any additional compositions, materials, components, elements, features, integers, operations, and/or process steps that materially affect the basic and novel characteristics are excluded from such an embodiment, but any compositions, materials, components, elements, features, integers, operations, and/or process steps that do not materially affect the basic and novel characteristics can be included in the embodiment.
Any method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed, unless otherwise indicated.
When a component, element, or layer is referred to as being âon,â âengaged to,â âconnected to,â or âcoupled toâ another element or layer, it may be directly on, engaged, connected or coupled to the other component, element, or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being âdirectly on,â âdirectly engaged to,â âdirectly connected to,â or âdirectly coupled toâ another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., âbetweenâ versus âdirectly between,â âadjacentâ versus âdirectly adjacent,â etc.). As used herein, the term âand/orâ includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and/or sections, these steps, elements, components, regions, layers and/or sections should not be limited by these terms, unless otherwise indicated. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer or section. Terms such as âfirst,â âsecond,â and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.
Spatially or temporally relative terms, such as âbefore,â âafter,â âinner,â âouter,â âbeneath,â âbelow,â âlower,â âabove,â âupper,â and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially or temporally relative terms may be intended to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.
Throughout this disclosure, the numerical values represent approximate measures or limits to ranges to encompass minor deviations from the given values and embodiments having about the value mentioned as well as those having exactly the value mentioned. Other than in the working examples provided at the end of the detailed description, all numerical values of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term âaboutâ whether or not âaboutâ actually appears before the numerical value. âAboutâ indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by âaboutâ is not otherwise understood in the art with this ordinary meaning, then âaboutâ as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. For example, âaboutâ may comprise a variation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in certain aspects, optionally less than or equal to 0.1%.
In addition, disclosure of ranges includes disclosure of all values and further divided ranges within the entire range, including endpoints and sub-ranges given for the ranges.
Example embodiments will now be described more fully with reference to the accompanying drawings.
The current technology pertains to solid-state batteries (SSBs), for example only, bipolar solid-state batteries, including a metal foam material (for example, as a current collector) and an electrothermal material foil (for example, as a self-heating element), and methods for forming and using solid-state batteries including metal foam materials and electrothermal material foils.
Solid-state batteries may include at least one solid component, for example, at least one solid electrode, but may also include semi-solid or gel, liquid, or gas components, in certain variations. Solid-state batteries may have a bipolar stacking design comprising a plurality of bipolar electrodes where a first mixture of solid-state electroactive material particles (and optional solid-state electrolyte particles) is disposed on or within a metal foam material on a first side of a current collector film, and a second mixture of solid-state electroactive material particles (and optional solid-state electrolyte particles) is disposed on or within a metal foam material on a second side of the current collector film that is parallel with the first side. The first mixture may include, as the solid-state electroactive material particles, cathode material particles. The second mixture may include, as solid-state electroactive material particles, anode material particles. The solid-state electrolyte particles in each instance may be the same or different. A solid-state electrolyte layer including a plurality of solid-state electrolyte particles may be disposed between the electrodes of adjacent cells. The electrothermal material foils may be disposed between adjacent current collector films and/or at terminal ends of the battery pack.
Such solid-state batteries may be incorporated into energy storage devices, like rechargeable lithium-ion batteries, which may be used in automotive transportation applications (e.g., motorcycles, boats, tractors, buses, mobile homes, campers, and tanks). The present technology, however, may also be used in other electrochemical devices, including aerospace components, consumer goods, devices, buildings (e.g., houses, offices, sheds, and warehouses), office equipment and furniture, and industrial equipment machinery, agricultural or farm equipment, or heavy machinery, by way of non-limiting example. In various aspects, the present disclosure provides a rechargeable lithium-ion battery that exhibits high temperature tolerance, as well as improved safety and good power capability and life performance.
An exemplary and schematic illustration of an all-solid-state electrochemical cell unit (also referred to as âsolid-state batteryâ and/or âbatteryâ) 20 that cycles lithium ions is shown in FIG. 1 . The battery 20 includes a negative electrode (i.e., anode) 22 , a positive electrode (i.e., cathode) 24 , and a solid state electrolyte layer 26 . The solid- state electrolyte layer 26 is a separating layer that physically separates the negative electrode 22 and the positive electrode 24 . The solid- state electrolyte layer 26 may be defined by a first plurality of solid- state electrolyte particles 30 . A second plurality of solid- state electrolyte particles 90 may be mixed with negative solid- state electroactive particles 50 in the negative electrode 22 , and a third plurality of solid- state electrolyte particles 92 may be mixed with positive solid- state electroactive particles 60 in the positive electrode 24 , so as to form a continuous electrolyte network, which may be a continuous lithium-ion conduction network. The negative solid- state electroactive particles 50 and the second plurality of solid- state electrolyte particles 90 may be disposed on or embedded within a porous material 100 A. The positive solid- state electroactive particles 60 and the third plurality of solid- state electrolyte particles 92 may be disposed on or embedded within a porous material 100 B.
A negative electrode current collector foil 32 may be positioned at or near the negative electrode 22 . For example, the negative electrode current collector foil 32 may be disposed on a top surface of a porous material 100 A. The porous material 100 A may provide support for the negative electrode current collector foil 32 such that the negative current collector foil 32 may have a thickness greater than or equal to about 2 μm to less than or equal to about 30 μm, and in certain aspects, optionally greater than or equal to about 2 μm to less than or equal to about 10 μm. The negative electrode current collector foil 32 may be formed from copper or any other appropriate electrically conductive material known to those of skill in the art.
A positive electrode current collector foil 34 may be positioned at or near the positive electrode 24 . For example, the positive electrode current collector foil 34 may be disposed on a top surface of a porous material 100 B. The porous material 100 B may provide support for the positive electrode current collector foil 34 such that the positive current collector foil 34 may have a thickness greater than or equal to about 2 μm to less than or equal to about 30 μm, and in certain aspects, optionally greater than or equal to about 2 μm to less than or equal to about 10 μm. The positive electrode current collector foil 34 may be formed from aluminum or any other electrically conductive material known to those of skill in the art.
The negative electrode current collector foil 32 and the positive electrode current collector foil 34 respectively collect and move free electrons to and from an external circuit 40 (as shown by the block arrows). For example, an interruptible external circuit 40 and a load device 42 may connect the negative electrode 22 (through the negative electrode current collector foil 32 ) and the positive electrode 24 (through the positive electrode current collector foil 34 ). The battery 20 can generate an electric current (indicated by arrows in FIG. 1 ) during discharge by way of reversible electrochemical reactions that occur when the external circuit 40 is closed (to connect the negative electrode 22 and the positive electrode 24 ) and when the negative electrode 22 has a lower potential than the positive electrode 24 . The chemical potential difference between the negative electrode 22 and the positive electrode 24 drives electrons produced by a reaction, for example, the oxidation of intercalated lithium, at the negative electrode 22 , through the external circuit 40 towards the positive electrode 24 . Lithium ions, which are also produced at the negative electrode 22 , are concurrently transferred through the solid- state electrolyte layer 26 towards the positive electrode 24 . The electrons flow through the external circuit 40 and the lithium ions migrate across the solid- state electrolyte layer 26 to the positive electrode 24 , where they may be plated, reacted, or intercalated. The electric current passing through the external circuit 40 can be harnessed and directed through the load device 42 (in the direction of the arrows) until the lithium in the negative electrode 22 is depleted and the capacity of the battery 20 is diminished.
The battery 20 can be charged or reenergized at any time by connecting an external power source (e.g., charging device) to the battery 20 to reverse the electrochemical reactions that occur during battery discharge. The external power source that may be used to charge the battery 20 may vary depending on the size, construction, and particular end-use of the battery 20 . Some notable and exemplary external power sources include, but are not limited to, an AC-DC converter connected to an AC electrical power grid though a wall outlet and a motor vehicle alternator. The connection of the external power source to the battery 20 promotes a reaction, for example, non-spontaneous oxidation of intercalated lithium, at the positive electrode 24 so that electrons and lithium ions are produced. The electrons, which flow back towards the negative electrode 22 through the external circuit 40 , and the lithium ions, which move across the solid- state electrolyte layer 26 back towards the negative electrode 22 , reunite at the negative electrode 22 and replenish it with lithium for consumption during the next battery discharge cycle. As such, a complete discharging event followed by a complete charging event is considered to be a cycle, where lithium ions are cycled between the positive electrode 24 and the negative electrode 22 .
Although the illustrated example includes a single positive electrode 24 and a single negative electrode 22 , as illustrated in FIG. 1 , the skilled artisan will recognize that the current discussion applies to various other configurations (such as illustrated in FIGS. 3 , 8 , and 10 - 12 ) including those having one or more cathodes and one or more anodes, as well as various current collectors and current collector films with electroactive particle layers disposed on or adjacent to or embedded within one or more surfaces thereof. Likewise, it should be recognized that the battery 20 may include a variety of other components that, while not depicted here, are nonetheless known to those of skill in the art. For example, the battery 20 may include a casing, a gasket, terminal caps, and any other conventional components or materials that may be situated within the battery 20 , including between or around the negative electrode 22 , the positive electrode 24 , and/or the solid- state electrolyte 26 layer.
The size and shape of the battery 20 may vary depending on the particular applications for which it is designed. Battery-powered vehicles and hand-held consumer electronic devices are two examples where the battery 20 would most likely be designed to different size, capacity, voltage, energy, and power-output specifications. The battery 20 may also be connected in series or parallel with other similar lithium-ion cells or batteries to produce a greater voltage output, energy, and power if it is required by the load device 42 . The battery 20 can generate an electric current to the load device 42 that can be operatively connected to the external circuit 40 . The load device 42 may be fully or partially powered by the electric current passing through the external circuit 40 when the battery 20 is discharging. While the load device 42 may be any number of known electrically-powered devices, a few specific examples of power-consuming load devices include an electric motor for a hybrid vehicle or an all-electric vehicle, a laptop computer, a tablet computer, a cellular phone, and cordless power tools or appliances, by way of non-limiting example. The load device 42 may also be an electricity-generating apparatus that charges the battery 20 for purposes of storing electrical energy.
With renewed reference to FIG. 1 , the solid- state electrolyte layer 26 provides electrical separation-preventing physical contact-between the negative electrode 22 and the positive electrode 24 . The solid- state electrolyte layer 26 also provides a minimal resistance path for internal passage of ions. In various aspects, the solid- state electrolyte layer 26 may be defined by a first plurality of solid- state electrolyte particles 30 . For example, the solid- state electrolyte layer 26 may be in the form of a layer or a composite that comprises the first plurality of solid- state electrolyte particles 30 . The solid- state electrolyte particles 30 may have an average particle diameter greater than or equal to about 0.02 μm to less than or equal to about 20 μm, optionally greater than or equal to about 0.1 μm to less than or equal to about 10 μm, and in certain aspects, optionally greater than or equal to about 0.1 μm to less than or equal to about 1 μm. The solid- state electrolyte layer 26 may be in the form of a layer having a thickness greater than or equal to about 5 μm to less than or equal to about 200 μm, optionally greater than or equal to about 10 μm to less than or equal to about 100 μm, optionally about 40 μm, and in certain aspects, optionally about 30 μm.
The solid- state electrolyte particles 30 may comprise one or more sulfide-based particles, oxide-based particles, metal-doped or aliovalent-substituted oxide particles, nitride-based particles, hydride-based particles, halide-based particles, and borate-based particles.
In certain variations, the oxide-based particles may comprise one or more garnet ceramics, LISICON-type oxides, NASICON-type oxides, and Perovskite type ceramics. For example, the garnet ceramics may be selected from the group consisting of: Li 7 La 3 Zr 2 O 12 , Li 6.2 Ga 0.3 La 2.95 Rb 0.05 Zr 2 O 12 , Li 6.85 La 2.9 Ca 0.1 Zr 1.75 Nb 0.25 O 12 , Li 6.25 Al 0.25 La 3 Zr 2 O 12 , Li 6.75 La 3 Zr 1.75 Nb 0.25 O 12 , and combinations thereof. The LISICON-type oxides may be selected from the group consisting of: Li 2+2 xZn 1âx GeO 4 (where 0<x<1), Li 14 Zn(GeO 4 ) 4 , Li 3+x (P 1âx Si x )O 4 (where 0<x<1), Li 3+x Ge x V 1âx O 4 (where 0<x<1), and combinations thereof. The NASICON-type oxides may be defined by LiMMâ²(PO 4 ) 3 , where M and Mâ² are independently selected from Al, Ge, Ti, Sn, Hf, Zr, and La. For example, in certain variations, the NASICON-type oxides may be selected from the group consisting of: Li 1+x Al x Ge 2âx (PO 4 ) 3 (LAGP) (where 0â¤xâ¤2), Li 1.4 Al 0.4 Ti 1.6 (PO 4 ) 3 , Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 , LiTi 2 (PO 4 ) 3 , LiGeTi(PO 4 ) 3 , LiGe 2 (PO 4 ) 3 , LiHf 2 (PO 4 ) 3 , and combinations thereof. The Perovskite-type ceramics may be selected from the group consisting of: Li 3.3 La 0.53 TiO 3 , LiSr 1.65 Zr 1.3 Ta 1.7 O 9 , Li 2xây Sr 1âx Ta y Zr 1ây O 3 (where x=0.75y and 0.60<y<0.75), Li 3/8 Sr 7/16 Nb 3/4 Zr 1/4 O 3 , Li 3x La (2/3âx) TiO 3 (where 0<x<0.25), and combinations thereof.
In certain variations, the metal-doped or aliovalent-substituted oxide particles may include, for example only, aluminum (Al) or niobium (Nb) doped Li 7 La 3 Zr 2 O 12 , antimony (Sb) doped Li 7 La 3 Zr 2 O 12 , gallium (Ga) doped Li 7 La 3 Zr 2 O 12 , chromium (Cr) and/or vanadium (V) substituted LiSn 2 P 3 O 12 , aluminum (Al) substituted Li 1+x+y Al x Ti 2âx Si y P 3ây O 12 (where 0<x<2 and 0<y<3), and combinations thereof.
In certain variations, the sulfide-based particles may include, for example only, a pseudobinary sulfide, a pseudoternary sulfide, and/or a pseudoquaternary sulfide. Example pseudobinary sulfide systems include Li 2 SâP 2 S 5 systems (such as, Li 3 PS 4 , Li 7 P 3 S 11 , and Li 9.6 P 3 S 12 ), Li 2 SâSnS 2 systems (such as, Li 4 SnS 4 ), Li 2 SâSiS 2 systems, Li 2 SâGeS 2 systems, Li 2 SâB 2 S 3 systems, Li 2 SâGa 2 S 3 system, Li 2 SâP<
CLAIMS
Claims ( 19 )
What is claimed is:
1. A solid-state battery configured to cycle lithium ions, the solid-state battery comprising:
one or more current collectors, wherein at least one of the one or more current collectors is in communication with one or more switches configured to move between an open position and a closed position, the open position corresponding to a first operational state of the solid-state battery and the closed position corresponding to a second operational state of the solid-state battery;
one or more electrodes disposed adjacent to the one or more current collectors, each electrode having a thickness greater than or equal to about 100 micrometers to less than or equal to about 3,000 micrometers and comprising a plurality of solid-state electroactive material particles;
and one or more electrothermal material foils comprising a resistor material and in electrical communication with the at least one of the one or more current collectors, wherein in the first operational state electrons flow through the one or more electrothermal material foils during cycling of the solid-state battery so as to initiate a heating mode, and in the second operational state electrons flow through the at least one of the one or more current collectors during cycling of the solid-state battery so as to initiate a non-heating mode;
wherein, in the closed position, the at least one of the one or more current collectors is in electrical communication with an external circuit and, in both the opened and closed positions, at least one of the one or more electrothermal material foils are in electrical communication with the external circuit.
2. The solid-state battery of claim 1 , wherein each of the one or more electrothermal material foils has a thickness greater than or equal to about 5 micrometers to less than or equal to about 200 micrometers, and
wherein the resistor material is selected from the group consisting of: nickel, stainless steel, copper, constantan, chromium, aluminum, iron, titanium, graphite, and alloys and combinations thereof.
3. The solid-state battery of claim 1 , wherein at least one of the one or more electrothermal material foils is patterned, the pattern comprising a plurality of void areas.
4. The solid-state battery of claim 1 , wherein the plurality of solid-state electroactive material particles are disposed on or embedded in a porous material having a porosity greater than or equal to about 80 vol. % to less than or equal to about 95 vol. %, an average pore size greater than or equal to about 2 micrometers to less than or equal to about 1,000 micrometers, and a thickness greater than or equal to about 100 micrometers to less than or equal to about 4,000 micrometers.
5. The solid-state battery of claim 4 , wherein the porous material is a metal foam selected from an aluminum (Al) foam, a nickel (Ni) foam, a copper (Cu) foam, a nickel-chromium (NiâCr) foam, a nickel-tin (NiâSn) foam, and a titanium (Ti) foam.
6. The solid-state battery of claim 4 , wherein the porous material is one of a carbon nanofiber three-dimensional foam, a graphene foam, a carbon cloth, a carbon fiber-embedded carbon nanotubes, and a graphene-nickel foam.
7. The solid-state battery of claim 4 , wherein the one or more electrodes comprise a first electrode and a second electrode, the first electrode comprising a first plurality of solid-state electroactive material particles and the second electrode comprising a second plurality of solid-state electroactive material particles,
wherein the at least one of one or more current collectors is a first current collector, and the first plurality of solid-state electroactive material particles is disposed adjacent to a first surface of the first current collector and the second plurality of solid-state electroactive material particles is disposed adjacent to a second surface of the first current collector that opposes the first surface.
8. The solid-state battery of claim 7 , wherein the first current collector comprises a first film and a second film parallel with the first film, the first film defining the first surface of the first current collector and the second film defining the second surface of the first current collector.
9. The solid-state battery of claim 8 , wherein the first film has a thickness less than or equal to about 10 micrometers and the second film has a thickness less than or equal to about 10 micrometers.
10. The solid-state battery of claim 7 , wherein the first electrode further comprises a plurality of solid-state electrolyte particles that are mixed with the first plurality of solid-state electroactive material particles and the plurality of solid-state electrolyte particles is also disposed on the porous material.
11. The solid-state battery of claim 7 , wherein the first plurality of solid-state electroactive material particles is disposed on a first section of the porous material, and
wherein the second plurality of solid-state electroactive material particles is disposed on a second section of the porous material.
12. The solid-state battery of claim 11 , wherein the plurality of solid-state electrolyte particles mixed with the first plurality of solid-state electroactive material particles is a first plurality of solid-state electrolyte particles, and
wherein the second electrode further comprises a second plurality of solid-state electrolyte particles that is mixed with the second plurality of solid-state electroactive material particles and the second plurality of solid-state electrolyte particles is also disposed on the porous material.
13. The solid-state battery of claim 11 , wherein the first current collector is a film disposed on a third portion of the porous material formed between the first and second portions of the porous material.
14. The solid-state battery of claim 4 , wherein the at least one of the one or more current collectors is a first current collector and the one or more current collectors comprises a second current collector that is parallel with the first current collector;
wherein the one or more electrodes comprise a first electrode comprising a first plurality of solid-state electroactive material particles disposed adjacent to the first current collector, and a second electrode comprising a second plurality of solid-state electroactive material particles disposed adjacent to the second current collector; and
wherein the solid-state battery further comprises a solid-state electrolyte layer comprising a plurality of solid-state electrolyte particles disposed between the first electrode and the second electrode.
15. The solid-state battery of claim 14 , wherein the solid-state electrolyte layer has a thickness greater than or equal to about 5 micrometers to less than or equal to about 100 micrometers and comprises:
a first sublayer comprising a first plurality of solid-state electrolyte particles, and
a second sublayer comprising a second plurality of solid-state electrolyte particles, wherein the first and second sublayers are the same or different.
16. A solid-state battery configured to cycle lithium ion, the solid-state battery comprising:
a first current collector;
a first electrode having a thickness greater than or equal to about 100 micrometers to less than or equal to about 3,000 micrometers disposed adjacent to the first current collector, the first electrode comprising a first plurality of solid-state electroactive material particles disposed on or embedded in a first porous material;
a second current collector parallel with the first current collector, wherein at least one of the first and second current collectors is in communication with one or more switches configured to move the solid-state battery between an open position and a closed position, wherein the open position corresponding to a first operational state of the solid-state battery and the closed position corresponding to a second operational state of the solid-state battery,
a second electrode having a thickness greater than or equal to about 100 micrometers to less than or equal to about 3,000 micrometers disposed adjacent to the second current collector, the second electrode comprising a second plurality of solid-state electroactive material particles disposed on or embedded in a second porous material;
a solid-state electrolyte layer disposed between the first electrode and the second electrode;
and one or more electrothermal material foils having a thickness greater than or equal to about 5 micrometers to less than or equal to about 200 micrometers and comprising a resistor material in electrical communication with at least one of the first and second current collectors, wherein in the first operational state electrons flow through the one or more electrothermal material foils during cycling of the solid-state battery so as to initiate a heating mode, and in the second operational state electrons flow through at least one of the first and second current collectors during cycling of the solid-state battery so as to initiate a non-heating mode,
wherein, in the closed position, at least one of the first current collector and the second current collector is in electrical communication with an external circuit and, in both the opened and closed positions, at least one of the one or more electrothermal material foils are in electrical communication with the external circuit.
17. The solid-state battery of claim 16 , wherein the first and second porous materials each have a porosity greater than or equal to about 80 vol. % to less than or equal to about 95 vol. %, an average pore size of greater than or equal to about 2 micrometers to less than or equal to about 1,000 micrometers, and a thickness greater than or equal to about 100 micrometers to less than or equal to about 4,000 micrometers.
18. The solid-state battery of claim 16 , wherein the resistor material is selected from the group consisting of: nickel, stainless steel, copper, constantan, chromium, aluminum, iron, titanium, graphite, and alloys and combinations thereof, and at least one of the one or more electrothermal material foils is patterned, the pattern comprising a plurality of void areas.
19. The solid-state battery of claim 16 , wherein at least one of the first and second current collectors comprises a first film and a second film parallel with the first film, the first and second films having a thickness less than about 10 micrometers.
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