The disclosure relates to batteries and more particularly to a thin film electrolyte with a gradient composition for use in batteries.
Batteries are a useful source of stored energy that can be incorporated into a number of systems. Rechargeable lithium-ion (“Li-ion”) batteries are attractive energy storage systems for portable electronics and electric and hybrid-electric vehicles because of their high specific energy compared to other electrochemical energy storage devices. In particular, batteries with a form of lithium (“Li”) metal incorporated into the negative electrode or anode afford exceptionally high specific energy (measured in Wh/kg) and energy density (measured in Wh/L) compared to batteries with conventional carbonaceous negative electrodes.
In Li-ion battery applications with Li metal anodes, unintended side reactions occur at the electrode/electrolyte interface. This side reaction consumes the electrode material, produces a solid-electrolyte interphase (SEI) layer, and consequently reduces the battery energy capacity. However, the SEI layer often does not substantially inhibit battery operation if it satisfies two criteria: (1) the SEI layer must be a Li ionic conductor, which allows the transport of Li ions for normal battery charging/discharging operations; and (2) the SEI layer must be a poor electronic conductor, preventing electron transport across the SEI layer. In contrast, if the material is both ionically and electronically conducting, the SEI layer may grow rather than passivate. Furthermore, Li metal is sometimes unintendedly deposited on top of the SEI layer rather than below the SEI layer, potentially leading to stranded Li upon cycling.
In view of the successful use of LiPON as a thin film electrolyte in battery applications, related lithium oxides and nitrides such as LiSiO, LiSiON, LiPSiON, LiPSiBON, and others may also be useful in such applications. However, stability calculations suggest that these materials can form SEI layers that are electronically and ionically conductive, which may inhibit their use in batteries. Stability calculations are performed using the convex hull analysis in multidimensional space. For example, suppose an objective is to find the lowest-energy materials at a given composition, such as Li4SiO4. Depending on the physics, it could be that the lowest total energy is achieved by one compound (e.g. Li4SiO4) or the phase separation of multiple compounds (e.g. 2(Li2O)+SiO2).
Typically, these total-energy calculations are performed via ab-initio computations in the density-functional theory formalism. A database is constructed with many such computations, and the “convex hull” is mapped out of lowest-energy compounds or groups of compounds. Projecting any point (such as Li4SiO4) onto the convex hull will give the decomposition products that provide the lowest energy. The “formation energy” of those products is the energy cost to form those products as opposed to keep them at some other endpoints. Importantly, the actual formation of these products depends on the kinetics of the reaction and is not easily predictable. Thus, the primary use of the analysis is to determine what products could possibly form.
During the cycling of a battery, the electrochemical potential of Li will change, so to find all SEI compositions that may form, the line between the electrolyte and the Li metal is examined, and that line is projected onto the convex hull. The decomposition products (intermediate vertices along the projected line) are further examined in order to test whether any of the products are electronic conductors (metals) by computing the predicted bandgap. A zero bandgap means there is a metal, whereas a nonzero bandgap indicates a semiconductor or insulator. This determination is subject to the usual constraints and accuracy of density-functional theory, but it is expected to be reasonably reliable to predict whether LiPSiBON compounds are insulators or metals, even if the bandgap is slightly inaccurate.
LiPON contains products that are electronic insulators (nonzero bandgap), usually Li3P+Li3N+Li2O (not shown). Therefore, the SEI layer is an electronic insulator, leading to good performance of a LiPON electrolyte with a stable SEI layer. These characteristics enable LiPON to be useful in thin film batteries. However, LiSiO and LiBO form LiSi and LiB compounds (possibly with trace oxygenation), respectively, which are metallic. The typical decomposition may be Li5SiN3+Li2O+Li21Si5, where the last product is a metal. This characteristic poses a challenge for using LiSiO/LiBO against Li metal since the equipotential of Li on all sides of LiSi/LiB compounds will cause more LiSiO/LiBO to decompose into LiSi/LiB compounds such that the SEI layer will continuously grow.
What is needed, therefore, is a thin film electrolyte with a compositional gradient in which the side of the electrolyte that adheres to the anode has greater compositions of materials that are electronically insulating. The remainder of the electrolyte has other compositions of materials that exhibit traditional electrolyte properties, such as mechanical strength, stability against the cathode material, ionic conductivity, and others. It would be advantageous to provide the compositional gradient of the electrolyte by use of a single, gradient-producing process. A thin film electrolyte with a compositional gradient comprising multiple, independently fabricated layers of different compositions would also be advantageous.
A battery cell in one embodiment includes a positive electrode, a negative electrode that includes lithium metal, and an electrolyte structure disposed between the negative electrode and the positive electrode, the electrolyte structure including a first side configured to contact the negative electrode and a second side spaced from the first side and facing the positive electrode, the first side and the second side defining a thickness, a first region disposed adjacent to the first side and extending towards the second side, the first region having a first composition of materials that is electronically insulating, and a second region disposed between the first region and the second side, the second region having a second composition of materials that is different than the first composition, the first region and the second region defining a compositional gradient across the thickness of the electrolyte structure.
A thin film electrolyte structure for a battery cell in one embodiment includes a first side configured to contact a lithium metal anode of the battery cell and a second side facing opposite the first side, the first side and the second side defining a thickness, a first region disposed adjacent to the first side and extending towards the second side, the first region having a first composition of materials that is configured to be stable against the lithium metal anode, and a second region disposed between the first region and the second side, the second region having a second composition of materials that is different than the first composition, the first region and the second region defining a compositional gradient across the thickness of the electrolyte structure.
For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the disclosure as would normally occur to one skilled in the art to which this disclosure pertains.
The cathode 104 includes a mixture of at least an active material and a matrix configured to conduct the primary ions of relevance to the cell 100. The active material in various embodiments includes a sulfur or sulfur-containing material (e.g., PAN-S composite or Li2S); an air electrode; Li-insertion materials such as NCM, LiNi0.5Mn1.5O4, Li-rich layered oxides, LiCoO2, LiFePO4, LiMn2O4; Li-rich NCM, NCA, and other Li intercalation materials, or blends thereof; or any other active material or blend of materials that react with and/or insert Li cations and/or electrolyte anions.
The matrix in various embodiments includes Li-conducting liquid, gel, polymer, or other solid electrolyte. Solid electrolyte materials in the cathode 104 may further include lithium conducting garnets, lithium conducting sulfides (e.g., Li2S—P2S) or phosphates, Li3P, LIPON, Li-conducting polymer (e.g., polyethylene oxide (PEO) or polycaprolactone (PCL)), Li-conducting metal-organic frameworks, Li3N, Li3P, thio-LISiCONs, Li-conducting NaSICONs, Li10GeP2S12, lithium polysulfidophosphates, or other solid Li-conducting material. Other materials in the cathode 104 may include electronically conductive additives such as carbon black, binder material, metal salts, plasticizers, fillers such as SiO2, or the like. The cathode materials are selected to allow sufficient electrolyte-cathode interfacial area for a desired design. The cathode 104 may be greater than 1 m in thickness, preferably greater than 10 μm, and more preferably greater than 40 μm. In one embodiment, the composition of the cathode 104 includes approximately 60 to 85 weight percent active material, approximately 3 to 10 weight percent carbon additive, and 15 to 35 weight percent catholyte.
The gradient-composition electrolyte 110 in the embodiment shown in
The first direction 116 (viewed leftward or rightward in
The gradient-composition electrolyte 110 of
The gradient-composition electrolyte 110 has greater compositions of materials that are electronically insulating on the anode-side 112 than on the cathode-side 114 so that the gradient-composition electrolyte 110 is stable against the anode 102. Such electronically insulating compositions generally include lithium, phosphorous, oxygen, fluorine, and nitrogen, which are known enhance electric resistivity. Such electronically insulating compositions more particularly include compositions that are closer to one or more of Li3P and Li3N. The greater compositions of materials that are electronically insulating are encompassed in a first region 113 of the gradient-composition electrolyte 110 with a thickness of about 500 nm or thinner measured from the anode-side 112. In other embodiments, the first region 113 containing the greater compositions of materials that are electronically insulating has a thickness of about 100 nm measured from the anode-side 112. As used herein, a thickness measured “from” an indicated side of an element or feature means that the thickness is measured from that indicated side in a direction of shortest extent towards the opposite of side of the element or feature. For example, since the anode side 112 and the cathode 114 side of the of the gradient-composition electrolyte 110 illustrated in
The gradient-composition electrolyte 110 has a second region 115 starting from an approximate end or boundary of the first region 113 and moving away from the anode 102 in the first direction 116 towards the cathode side 114. In the second region 115, the gradient-composition electrolyte 110 has other compositions that exhibit more typical electrolyte properties, such as mechanical strength, stability against the cathode material, ionic conductivity, and other properties. The thickness of the second region 115 of the gradient-composition electrolyte 110 varies depending on the thickness of the first region 113 and the total thickness of the gradient-composition electrolyte 110. For instance, in an embodiment of the gradient-composition electrolyte 110 with a total thickness of 5,000 nm and a first region 113 thickness of 500 nm, the second region 115 will have a thickness of approximately 4,500 nm. In another embodiment of the gradient-composition electrolyte 110 with a total thickness of 25,000 nm and a first region 113 thickness of 100 nm, the second region 115 will have a thickness of approximately 24,000 nm. In the embodiment of
In the gradient-composition electrolyte 110 shown in
One difference between the cell 100 and the cell 200 is that the gradient-composition electrolyte 210 has an auxiliary side 214 that is configured to adhere to or otherwise contact the auxiliary electrolyte 211. The auxiliary side 214 of the gradient-composition electrolyte 210 defines an auxiliary-facing surface 224 that faces an auxiliary surface 226 of the auxiliary electrolyte 211. The gradient-composition electrolyte 210 has a second region 215 disposed between the first region 213 and the auxiliary side. In the second region 215, the gradient-composition electrolyte 210 has other compositions that exhibit more typical electrolyte properties, such as mechanical strength, stability against the cathode material, ionic conductivity, and other properties. Another difference between the cell 100 and the cell 200 is that the total thickness of the gradient-composition electrolyte 210 is approximately 1,000 to 5,000 nm, which is smaller than the total thickness of the gradient-composition electrolyte 110 of
The auxiliary electrolyte 211 is configured to have high ionic conductivity. The thickness of the auxiliary electrolyte 211 is in the range of 10 to 20 μm. The auxiliary electrolyte 211 in one embodiment is configured as a liquid electrolyte in pores of conventional polyolefin separator. The auxiliary electrolyte 211 in another embodiment is configured as a polymer separator. In yet another embodiment, the auxiliary electrolyte 211 is configured as a ceramic separator such as sulfide with approximately 1e-3 S/cm or higher.
The first layer 312 has a first anode-facing side 318 and a first cathode-facing side 320 spaced from the first anode-facing side 318 in the first direction. The first anode-facing side 318 of the gradient-composition electrolyte 310 is configured to adhere to or otherwise contact the anode 102. The second layer 314 has a second anode-facing side 322 and a second cathode-facing side 324 spaced from the second anode-facing side 322 in the first direction. The second anode-facing side 322 of the second layer 314 is configured to adhere to or otherwise contact the first cathode-facing side 320 of the first layer 312. The third layer 316 has a third anode-facing side 326 and a third cathode-facing side 328 spaced from the third anode-facing side 326 in the first direction. The third anode-facing side 326 of the third layer 316 is configured to adhere to or otherwise contact the second cathode-facing side 324 of the second layer 314. The third cathode-facing side 328 of the third layer 316 is configured to adhere to or otherwise contact the cathode 104.
The first layer 312 has a thickness of approximately 50 nm and contains LiPON or another electrolyte that has relatively poor ionic conductivity (i.e., approximately 1e-6 S/cm) and resistivity of approximately 5 Ωcm2 and desirable properties for an SEI such as electronic resistivity. The second layer 314 has a thickness of approximately 0.5 μm and contains LiSiPON or another glass that is electronically conducting but has moderate ionic conductivity (i.e., approximately 1e-5 S/cm) and resistivity of 5 Ωcm2. The third layer 316 has a thickness of approximately 20 μm and constitutes a separator with high-conductivity. The third layer 316 in one embodiment is configured as a liquid electrolyte in pores of conventional polyolefin separator. The third layer 316 in another embodiment is configured as a polymer separator. In yet another embodiment, the third layer 316 is configured as a ceramic separator such as sulfide with approximately 1e-3 S/cm or higher and resistivity of 2 Ωcm2. Assuming negligible interfacial impedance, the entire gradient-composition electrolyte 310 has a resistivity of approximately 12 Ωcm2.
The process 400 has a number of technical advantages: (1) It is expected to be easier and cheaper to produce the gradient-composition electrolyte than multiple layers of electrolyte stacked upon each other, because the entire electrolyte is grown with a single process. (2) The anode-facing layer has a composition and thickness than can be controlled easier than a naturally-forming SEI layer. (3) The adhesion between different parts of the electrolyte is expected to be better (causing lower interfacial resistance) because they are grown as one unit.
The gradient-composition electrolyte disclosed herein as well as batteries and devices which include the gradient-composition electrolyte can be embodied in a number of different types and configurations. The following embodiments are provided as examples and are not intended to be limiting.
Embodiment 1: An electrolyte with a compositional gradient (henceforth GCE, gradient-composition electrolyte), where one side has the property of being stable against a Li-metal anode, and the rest has other desired properties such as mechanical strength and ionic conductivity.
Embodiment 2: Where the GCE contains any or all of: lithium, silicon, phosphorous, boron, oxygen, nitrogen, and fluorine.
Embodiment 3: Where some or all of the GCE is fabricated via sputtering.
Embodiment 4: Where the compositional gradient is continuum-fabricated at one point (such as a substrate surface) via a gradient-growth method, such as gradient sputtering.
Embodiment 5: Where the compositional gradient is discrete, formed by stacking multiple electrolyte layers upon each other, whether independently fabricated or by each layer forming a substrate for processing the next layer.
Embodiment 6: Where the entire GCE is placed upon another supporting structure; or is directly applied to the cathode.
Embodiment 7: Where the GCE next to the anode contains any or all of: lithium, phosphorous, oxygen, fluorine, and nitrogen; which are known enhance electric resistivity.
Embodiment 8: Where the electronically-insulating component of the GCE (anode-facing layer) has thickness of 500 nm or less, and ideally less than 100 nm.
Embodiment 9: Where the sputtered part of the GCE is 5 μm or less, and ideally less than 1 μm.
While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected.
This application claims the benefit of U.S. Provisional Application 62/609,936, filed Dec. 22, 2017, the disclosure of which is incorporated herein by reference in its entirety.
This invention was made with government support under DE-AR0000775 awarded by the U.S. Department of Energy, Advanced Research Projects Agency—Energy (ARPA-E). The government has certain rights in the invention.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2018/084983 | 12/14/2018 | WO | 00 |
Number | Date | Country | |
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62609936 | Dec 2017 | US |