EP-4736251-A2 - INTERNALLY ENCLOSED SUPPORT SYSTEM FOR BATTERIES, FABRICATION TECHNIQUES AND APPLICATIONS FOR THE SAME

EP4736251A2EP 4736251 A2EP4736251 A2EP 4736251A2EP-4736251-A2

Abstract

Electrochemical cells and batteries including a polymeric support system in lieu of a conventional, metal-based structures. The polymer support system provides mechanical strength and mechanical flexibility to the electrochemical cells in a manner that is advantageously greater than what is provided by conventional structures, in spite of the fact that the polymer support system contributes far less to the overall weight of the electrochemical cells. The polymer support system may be present in an interior volume of an electrochemical cell, e.g., in the form of a continuous polymeric network penetrating various components of the electrochemical cell. The penetrating structures may include the anode and cathode current collectors, and any/all components therebetween. Additionally or alternatively, the polymer support system may include various forms of external support structures, chemical anchors, coatings and/or casings of the electrochemical cell. Additional advantageous characteristics include improved recyclability and increased longevity of the electrochemical cells.

Inventors

BAUCOM, JESSE
FAVORS, Zach
ANZELMO, Bryce
RHODES, KEVIN

Assignees

Lyten, Inc.

Dates

Publication Date: 20260506
Application Date: 20240502

Claims (20)

1. An electrochemical cell, comprising: an anode; a cathode; a porous separator, directly ionically coupled or indirectly ionically coupled to the anode and the cathode; and a plurality of precursors of a polymer support system present in an interior volume of the anode, an interior volume of the porous separator, and an interior volume of the cathode; and wherein the plurality of precursors of the polymer support system are arranged in one or more continuous pathways extending from the anode to the cathode.
2. The electrochemical cell as recited in claim 1, wherein the plurality of precursors of the polymer support system is selected from the group consisting of: one or more polymeric precursors; one or more initiators; one or more binders; one or more terminators; one or more crosslinkers; one or more carbonaceous materials; one or more scavenging materials; one or more thermosetting materials; one or more solvent systems; one or more phase change materials; one or more lithium ion transporting compounds; and combinations thereof.
3. The electrochemical cell as recited in claim 2, wherein the one or more polymeric precursors are precursors of one or more compounds selected from the group consisting of: polytrimethylene terephthalate, poly ethersulfone, high density polyethylene, low density polyethylene, linear low density polyethylene, polypropylene, polyolefin copolymers, polystyrene, polystyrene copolymers, polythene, polyvinyl halides, polyvinyl alcohols, polytetrafluoroethylene (TEFLON(R)), poly acrylates, polymethacrylates, polyesters, polyvinylchloride, fluoropolymers, polyamides, polyamide-imides, polyether imides, polyphenylene sulfides, polysulfones, polyacetals, polycarbonates, polyphenylene oxides, polyurethanes, thermoplastic elastomers, epoxies, alkyds, melamines, phenolics, ureas, vinyl esters, hybridized crosslinking polymers, cyanate esters, polyurethanes, acrylonitric butadiene styrene (ABS) and polyacrylonitrile (PAN); ethylene vinyl alcohol, poly(methyl methacrylate) (PMMA), polyvinyl cinnamate, polyisoprene, , polyimides, styrenic block copolymers, bitumen, nitrile rubber, polycarbonate, poly etherimide (PEI), poly(pheylene sulfide) (PPS), poly etheretherketone (PEEK), poly etherketones (PEK), and combinations thereof.
4. The electrochemical cell as recited in claim 2, wherein the one or more initiators are selected from the group consisting of: moisture-based initiators, exothermic initiators, endothermic initiators, radical-generating compounds, sources of electromagnetic radiation, and combinations thereof.
5. The electrochemical cell as recited in claim 2, wherein the one or more binders are selected from the group consisting of: polyacrylate, polyacrylate, polyacrylamide (PAM), cyanoacrylates, aliphatic amines, polyamides, amidoamines, cyclophatic amines, aromatic amines, vinyltrimethoxy silane, and combinations thereof.
6. The electrochemical cell as recited in claim 2, wherein the one or more crosslinkers are selected from the group consisting of: amine-based chemicals, polycarbamides, [polyurea], polyamides, dicyandiamide, cycloalpahtic amines, boron trifluoride, amidoamines, aliphatic amines, tetraglycidyldiaminodiphenylmethane, diethyltoluene diamine, aromatic amine curing agents, and combinations thereof.
7. The electrochemical cell as recited in claim 2, wherein the one or more carbonaceous materials are selected from the group consisting of: carbon black, graphite, pyrolytic graphite, graphene (preferably three-dimensional graphene (3DG), graphene nanoparticles, and/or graphene platelets), single-walled carbon nanotubes (SWCNT), multi-walled carbon nanotubes (MWCNT), carbon nanotubes, carbon nano-onions (CNOs), necked CNOs, carbon nanospheres, fullerenes, hybrid fullerenes, and combinations thereof.
8. The electrochemical cell as recited in claim 2, wherein the one or more scavenging materials are selected from the group consisting of: polypropylene (PP), polyacrylate polyols, phenolic antioxidants, n-octyltriethoxysilane, n- propyltriethoxysilane, trimethylsilyl)isothiocyanate (TMSNCS), aminosilan-based compounds, copper-containing compounds, zinc-containing compounds, iron- containing compounds, poly acrylates, volcanic ash, talc, mica, alumina, silica, cellulose-based materials, metallic reducing agents, metal halides, ascorbic acid, sodium bicarbonate, and combinations thereof.
9. The electrochemical cell as recited in claim 2, wherein the one or more thermosetting materials are selected from the group consisting of: epoxies, phenocarboxylic acids (phenolic), bismaleimides, cyanates, esters, polybenzoxazines, crosslinking polymers, photopolymers, carbon fibers, and combinations thereof.
10. The electrochemical cell as recited in claim 2, wherein the one or more solvent systems comprise one or more compounds selected from the group consisting of: dimethyl siloxane (DMSO), tetrabutylammonium hydroxide (TBA) and/or dimethyl formamide (DMF), 1,2- dimethoxyethane (DME), tetrahydrofuran (THF), triethylene glycol dimethyl ether (TEGDME), 2-methyl-2-oxazoline (MOZ), 1,3-Dioxolane (DOL), 3,3-dimethyloxetane (DM0), 2-ethyl-2-oxazoline (EOZ), e- caprolactone (CL), and combinations thereof.
11. The electrochemical cell as recited in claim 2, wherein the one or more lithium ion transporting compounds are selected from the group consisting of: palladium (II) oxide, lithium cobalt oxide (LiCoO2), lithium lanthanides, diphenyliodonium hexafluorophosphate (DPIHFP), lithium borohydride (LiBFL) lithium bis(trifluoromethanesulfonyl)imide (LiTFSI) (LiC2p6NO4S2), lithium thiophosphates, NASICON, Lii. 3 Alo.3Tii.7(P0 4 )3 (LATP)), perovskite, LiosLaosTiOs, (LLTO), lithium azide (Li 3 N), argyrodite (LiePSsCl), and combinations thereof.
12. The electrochemical cell as recited in claim 1, comprising an anode current collector electrically coupled to the anode, and a cathode current collector electrically coupled to the cathode.
13. The electrochemical cell as recited in claim 12, wherein the plurality of precursors of the polymer support system are also present in an interior volume of the anode current collector.
14. The electrochemical cell as recited in claim 12, wherein the plurality of precursors of the polymer support system are also present in an interior volume of the cathode current collector.
15. The electrochemical cell as recited in claim 12, wherein at least some of the one or more continuous pathways extend from the anode current collector to the cathode current collector.
16. The electrochemical cell as recited in claim 1, wherein the electrochemical cell is arranged in a jelly-roll configuration and contained within an enclosure.
17. The electrochemical cell as recited in claim 1, wherein the plurality of precursors of the polymer support system are also present within interstitial spaces between rolled layers of the electrochemical cell.
18. The electrochemical cell as recited in claim 1, wherein the plurality of precursors are present in an amount ranging from about 1 wt% of a total weight of the electrochemical cell to about 20 wt% of a total weight of the electrochemical cell.
19. The electrochemical cell as recited in claim 1, wherein the polymer support system comprises one or more continuous, interpenetrating pathways present in an interior volume of the electrochemical cell and oriented substantially perpendicular to a longitudinal axis of the anode, the cathode, and the separator.
20. The electrochemical cell as recited in claim 1 , comprising one or more external components at least partially surrounding the electrochemical cell.

Description

INTERNALLY ENCLOSED SUPPORT SYSTEM FOR BATTERIES, FABRICATION TECHNIQUES AND APPLICATIONS FOR THE SAME FIELD OF THE INVENTION [0001] The present invention relates to battery technology, and more particularly to providing a polymeric support system configured to mechanically support and/or protect components of an electrochemical cell. BACKGROUND [0002] Batteries, particularly lithium-based batteries, are known to experience volumetric change over the course of operational lifetime, due to formation of gases during normal cycling and operation of the battery. This can lead to expansion of and within the electrochemical cell, including possible separation and delamination between the electrodes. As a result, ion transfer paths through the electrochemical cell are degraded, to the point of loss and ultimate failure of the cell. [0003] Conventionally, expansion caused by such volumetric change is addressed by adding a compressive structure, typically a metal such as aluminum or stainless steel, to the battery structure. Most commonly, a metal casing or bands surrounding the electrochemical cell are implemented as the compressive structure. However, using conventional metal-based compressive structures undesirably adds substantial weight and cost to the battery. Typically, these metallic compressive structures represent up to 65% of the total weight of the overall battery. [0004] The necessary added mass of the metal is particularly undesirable as it contributes to overall fabrication cost (both in terms of material cost and cost of machining and assembling the battery), as well as cost of transporting starting materials and final product from various sources to ultimate destinations. Further still, adding weight to the battery limits the performance of the machine utilizing the battery as a power source. Taking an electric vehicle as an example, as battery weight increases, so does fuel cost (either in the form of fuel consumed to charge the battery, or in the form of alternative fuel needed to power the vehicle itself), while range, carrying capacity, etc. of the vehicle are reduced. [0005] As such, there is thus a need for addressing these and/or other issues associated with the prior art. SUMMARY [0006] Compositions of matter, suitable systems implementing said compositions of matter, methods of fabricating such compositions of matter and corresponding systems, as well as various applications for improving, among other characteristics, mechanical strength of batteries are disclosed according to various aspects, implementations, and embodiments of the inventive concepts presented herein. [0007] Principally, the inventive concepts include using a polymer-based support system as the compressive structure for preventing separation and delamination of components within an electrochemical cell. The polymeric support system may be provided in the form of a casing surrounding the electrochemical cell, a continuous network of structurally coupled polymer(s) present throughout the internal volume of the electrochemical cell, a plurality of interpenetrating supports arranged within the electrochemical cell (and optionally, but preferably, anchored to an external surface of the cell and/or a polymeric casing surrounding the exterior of the electrochemical cell), a coating applied to an exterior of the electrochemical cell and/or between layers of the electrochemical cell, or any combination of such arrangements, according to various aspects of the presently disclosed inventive concepts. [0008] To further reduce overall mass of the inventive electrochemical cells, as well as provide mechanical “anchors” for polymeric support system present within the cell, either or (preferably) both the anode, the anode current collector(s), the cathode, and the cathode current collector(s) may be perforated, may be porous, may be configured as a mesh, expanded metal, or other configuration that would be appreciated by a person having ordinary skill in the art upon reading the present disclosure as suitable for use as an anchor or other physical coupling between the polymeric support system and components of the electrochemical cell, or otherwise allowing polymeric precursors and/or polymers and accompanying compounds to occupy portion(s) of the interior volume of the corresponding component of the electrochemical cell. Moreover, to facilitate maximum improvement to mechanical strength, the polymeric support system within the electrochemical cell forms at least one, preferably many, continuous pathways between the perforated current collectors, lending mechanical (particularly tensile) strength within the electrochemical cell. [0009] The polymeric support system may be implemented with, on, and/or within the cell in any suitable manner, including but not limited to structural arrangements, methods and/or mechanisms for curing the polymeric support system, timing of curing the polymer support, etc. For instance, according to various