KR-102961789-B1 - System and method for a composite solid-state battery cell having an ion-conducting polymer electrolyte

KR102961789B1KR 102961789 B1KR102961789 B1KR 102961789B1KR-102961789-B1

Abstract

A system and method for a slurry for coating an electrode structure are provided. In one example, the method may include the steps of dispersing a solid ion-conducting polymer material in at least a first portion of a solvent to form a suspension by mixing in one or both of high shear and low shear, dispersing one or more additives in the suspension by mixing in one or both of high shear and low shear, and then mixing a second portion of the solvent with the suspension to form a slurry by mixing in one or both of high shear and low shear. Thus, a slurry comprising a solid ion-conducting polymer material can be applied as a coating for a solid-state battery cell, which can reduce resistance to lithium-ion transport and improve mechanical stability compared to a conventional solid-state battery cell.

Inventors

호퍼트 웨슬리
로자스 아드리아나 에이.
로먼 데이비드 엠.
부아닉 루시엔
존슨 데릭 씨.
시스크 브라이언
치우 브라이언
질루리 토마스

Assignees

에이일이삼 시스템즈 엘엘씨

Dates

Publication Date: 20260507
Application Date: 20200701
Priority Date: 20190701

Claims (20)

Step of dividing the solvent into two parts; According to the order of steps, a step of mixing a solid ion-conducting polymer material having an ion conductivity greater than 1 x 10⁻⁵ S/cm at room temperature, wherein, when the solid ion-conducting polymer material is in a glassy state at room temperature, a suspension is formed in a first portion of the solvent, and the first portion of the solvent is 45 to 55 weight% of the total solvent content; A step of mixing a first additive into the above suspension; and The step of mixing the first additive into the suspension, and then mixing a second portion of the solvent with the suspension to form a slurry having a solid content of 25 to 80 weight%, a d50 particle size of less than 30 μm, a Hegman gauge of less than 90 μm, and a viscosity of 500 to 2800 cps at 85 Hz; A method wherein the above mixing includes mixing in a high shear axis and mixing in a low shear axis, wherein the low shear axis is 10 to 55 rpm.
In paragraph 1, The above high-shear axis is 0 to 1500 rpm; or The above high-shear axis is 0 to 3500 rpm, and the above low-shear axis is 10 to 40 rpm; or A method in which the high shear axis is 0 to 1300 rpm and the low shear axis is 10 to 45 rpm.
In any one of paragraphs 1 to 2, The above slurry has a d10 particle size of less than 1 μm, a d90 particle size of less than 60 μm, and a d99 particle size of less than 140 μm; or The above Hegman gauge is less than 80 μm, method.
In paragraph 1, The above mixing includes the mixing at the high shear and the mixing at the low shear simultaneously; or The amount of the first portion of the solvent and the amount of the second portion of the solvent are equal within a deviation of 5%; or The first additive above comprises an electrode active material, a binder, a surfactant, or an inorganic ceramic; or The step of mixing the second portion of the solvent with the suspension to form the slurry occurs under vacuum; or The step of mixing the first additive into the suspension is: A method comprising the step of mixing the first additive and one or more additional additives in the above suspension.
In paragraph 4, The first additive mentioned above is an inorganic ceramic; The above one or more additional additives are the binder and the surfactant; The step of mixing the first additive and the one or more additional additives in the above suspension is: A step of mixing the binder and the surfactant in a third portion of the solvent to form a solution; A step of mixing the inorganic ceramic into the above solution; A step of mixing the inorganic ceramic into the solution, and then dividing the solution into portions; A step of mixing a portion of the solution in the above suspension; then A method comprising the step of mixing the remainder of the solution in the above suspension.
In paragraph 4, The first additive mentioned above is an electrode active material; The step of mixing the solid ion-conducting polymer material into the first portion of the solvent to form the suspension is: A step of dividing the above binder into parts; A step of mixing a first portion of the binder with a first portion of the solvent to form a first solution; A step of dividing the above first solution into portions; A step of mixing an electronic conductor into a first portion of the first solution to form the above suspension; and The step of mixing the solid ion-conducting polymer material and a second portion of the first solution in the suspension; The step of mixing the first additive into the suspension is: A method comprising the step of mixing the electrode active material and the remainder of the first solution in the suspension.
In paragraph 6, The step of mixing the electrode active material and the remaining portion of the first solution in the suspension is: A step of dividing the above-mentioned first additive into portions; A step of mixing the first portion of the electrode active material and the third portion of the first solution with the suspension for 45 to 120 minutes; and then A method comprising the step of mixing a second portion of the electrode active material and a fourth portion of the first solution with the suspension for 2 to 16 hours.
As a slurry for forming a coating on an electrode structure, A solid ion-conducting polymer material having an ion conductivity greater than 1 x 10⁻⁵ S/cm at room temperature and being in a glassy state at room temperature; solvent; and It comprises one or more additives including an electrode active material, a binder, a surfactant, and an inorganic ceramic, and The above slurry has a solid content of 25 to 80 weight%, a d50 particle size of less than 30 μm, a Hegman gauge of less than 90 μm, and a viscosity of 500 to 2800 cps at 85 Hz, and the slurry is formed from a process of sequentially mixing the solid ion-conducting polymer material, the solvent, and one or more additives, and the process comprises: A step of dividing the above solvent into two parts; A step of mixing the solid ion-conducting polymer material into a first portion of the solvent to form a suspension, wherein the first portion of the solvent is 45 to 55 weight percent of the total solvent content; A step of mixing one or more additives into the above suspension; and The method includes the step of mixing one or more additives into the suspension, and then mixing a second portion of the solvent with the suspension to form the slurry. A slurry, wherein the above mixing includes mixing in a high-shear axis and mixing in a low-shear axis, and the low-shear axis is 10 to 55 rpm.
In paragraph 8, The above slurry is a slurry having a d10 particle size of less than 1 μm, a d90 particle size of less than 60 μm, and a d99 particle size of less than 140 μm.
As a coated hybrid electrode, Anode entire house; Cathode house whole; Anode material coating; Cathode material coating; and It includes a solid polymer electrolyte coating formed as a separator; The anode material coating, the cathode material coating, and the solid polymer electrolyte coating are each formed from a first slurry, a second slurry, and a third slurry, and each of the first slurry, the second slurry, and the third slurry is: Step of dividing the solvent into two parts; According to the order of steps, a step of mixing a solid ion-conducting polymer material having an ion conductivity greater than 1 x 10⁻⁵ S/cm at room temperature, wherein when the solid ion-conducting polymer material is in a glassy state at room temperature, a step of mixing the solid ion-conducting polymer material to form a suspension in a first portion of the solvent; A step of mixing an additive into the above suspension; and Formed by the step of mixing the additive into the suspension, and then mixing a second portion of the solvent with the suspension to form a composition having a solid content of 25 to 80 weight%, a d50 particle size of less than 30 μm, a Hegman gauge of less than 90 μm, and a viscosity of 500 to 2800 cps at 85 Hz; A coated hybrid electrode, wherein the above mixing includes mixing in a high-shear axis and mixing in a low-shear axis, and the low-shear axis is 10 to 55 rpm.
In Paragraph 10, The Hegman gauge of the first slurry is less than 50 μm and the viscosity of the first slurry is 2000 to 2600 cps at 85 Hz; or The solid content of the second slurry is 25 to 65 weight%, the Hegman gauge of the second slurry is less than 80 μm, and the viscosity of the second slurry is 1100 to 2800 cps at 85 Hz; or A coated hybrid electrode, wherein the solid content of the third slurry is 25 to 55 weight%, the d50 particle size of the third slurry is less than 15 μm, and the viscosity of the third slurry is 500 to 2200 cps at 85 Hz.
In Article 10 or Article 11, The solid polymer electrolyte coating is disposed between the anode material coating and the cathode material coating; The above-described solid polymer electrolyte coating is a coated hybrid electrode having a composition different from that of the second region adjacent to the anode material coating in the first region adjacent to the cathode material coating.
In Paragraph 10, It further includes a cathode separator interface coating disposed between the cathode material coating and the solid polymer electrolyte coating; The above cathode separation membrane interface coating comprises the above solid ion-conducting polymer material; The above-mentioned cathode separator interface coating is formed from a fourth slurry, wherein the fourth slurry has a solid content of 25 to 80 weight%, a d50 particle size of less than 30 μm, a Hegman gauge of less than 50 μm, and a viscosity of 2000 to 2600 cps at 85 Hz, and is a coated hybrid electrode.
In Paragraph 10, It further includes an anode separator interface coating disposed between the anode material coating and the solid polymer electrolyte coating; The above anode separation membrane interface coating comprises a solid ion-conducting polymer material; The above anode separator interface coating is formed from a fifth slurry, wherein the fifth slurry has a solid content of 25 to 75 weight%, a d50 particle size of less than 30 μm, a Hegman gauge of less than 90 μm, and a viscosity of 500 to 2600 cps at 85 Hz, and is a coated hybrid electrode.
In Paragraph 10, A first tab protection strip disposed between the anode current collector and the anode material coating; and It further includes a second tab protection strip disposed between the cathode current collector and the cathode material coating; A coated hybrid electrode, wherein the first tab protection strip and the second tab protection strip are each formed from a sixth slurry and a seventh slurry, and each of the sixth slurry and the seventh slurry has a solid content of 3 to 40 weight%, a d50 particle size of less than 5 μm, a Hegman gauge of less than 30 μm, and a viscosity of 500 to 3000 cps at 85 Hz.
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Description

System and method for a composite solid-state battery cell having an ion-conducting polymer electrolyte Cross-reference regarding related applications This application claims priority to U.S. Provisional Application No. 62/869,407, filed July 1, 2019, with the title of the invention “System and method for a composite solid-state battery cell having an ion-conducting polymer electrolyte”. The entire contents of the application identified above are incorporated herein by reference for all purposes. This description generally relates to a system and method for a solid-state battery cell comprising an ion-conducting polymer material. The energy density of a secondary battery is an important performance index because it describes how much work can be done per unit mass or volume, when calculated in terms of weight or volume, respectively. In the context of automotive applications, this measurement is important because it indicates the distance a vehicle can travel before requiring a charge, in relation to how much of the vehicle's total mass or volume is dedicated to the module responsible for the vehicle's energy storage. The energy density of composite energy storage devices is influenced not only by the theoretical weight or volume capacity of the electrode active material but also by the amount, mass, or volume of the electrode active material contained within. Furthermore, the packing efficiency of the materials containing the energy storage device affects energy density; this results in inefficiencies in the form of porosity or free volume, which manifest as increased volume for a given capacity, or a decrease in capacity for a fixed volume. Porosity or free volume caused by inefficient packing also has the effect of increased resistance because the voids within the electrode or electrolyte layer obstruct the path for charged species to move. As internal resistance increases, the power characteristics of the battery decrease, leading to inferior performance when high charge or discharge rates are required. In the context of conventional lithium-ion batteries, a certain degree of porosity may be permissible and can be functionally interesting, as these spaces penetrate into the liquid electrolyte to facilitate the transport of lithium ions from the active material of one electrode to another. These ion transport media provide a high level of mobility for lithium ions but present the disadvantage of high flammability, which poses safety issues in the context of automobiles or other transportation applications. It is desired to eliminate the risks associated with the flammability of the liquid electrolyte components of conventional lithium-ion batteries, which has led to interest in replacing liquid electrolytes with solid-state electrolytes; consequently, it is necessary to eliminate any non-functional free volume within the overall battery structure to optimize the aforementioned performance characteristics. Solid-state electrolytes exist in various forms, including inorganic oxides and sulfides, and, for example, organic materials include a continuum from gel-polymers to solid polymers. FIG. 1a illustrates a schematic structural diagram of a first exemplary configuration of a coated hybrid electrode. FIG. 1b illustrates a schematic structural diagram of a second exemplary configuration of a coated hybrid electrode. FIG. 2 illustrates a first exemplary method for forming a slurry for applying a coating to an electrode structure. FIG. 3 illustrates a second exemplary method for forming a slurry for applying a coating to an electrode structure. FIG. 4 illustrates a third exemplary method for forming a slurry for applying a coating to an electrode structure. FIG. 5 illustrates an exemplary method for forming a coating on an electrode structure through a slurry-based coating process. Figure 6 shows a plot illustrating the bimodal particle size distribution in a slurry for cathode material coating. Figure 7 shows a plot illustrating the particle size distribution in a slurry for cathode material coating. Figure 8 shows a plot illustrating viscosity versus shear rate in a slurry for cathode material coating. Figure 9 illustrates a process flow diagram for forming a slurry for a cathode material coating. Figure 10 shows a scanning electron microscope (SEM) image of the particle size distribution in a slurry for cathode material coating. Figure 11 shows a plot illustrating the particle size distribution in a slurry for anode material coating. Figure 12 shows a plot illustrating viscosity versus shear rate in a slurry for anode material coating. FIG. 13 illustrates a first process flow diagram for forming a slurry for anode material coating. FIG. 14 illustrates a second process flow diagram for forming a slurry for anode material coating. Figure 15 shows a plot illustrating the particle size distribution in a slurry for membrane coating. Figure 16 shows a plot illustrating viscosity versus shear rate in a slurry for