Patent Application
20220352521
The present invention relates generally to electrochemical cells, and more specifically, to electrochemical cells including an integrated electrode and separator.
There has been considerable interest in recent years in developing high energy density rechargeable batteries with lithium-containing anodes. A typical manufacturing process for such batteries often includes multiple steps, e.g., in which individual components of the batteries are separately fabricated and later combined to form the batteries. Batteries fabricated via such a multi-step process may have certain disadvantages such as increased complexity of manufacturing and/or relatively lower specific energies and/or energy densities. Accordingly, articles and methods for reducing the complexity of manufacturing, increasing specific energy and energy density of the battery, and/or other improvements would be beneficial.
The present invention relates generally to electrochemical cells, and more specifically, to electrochemical cells including an integrated electrode and separator. The subject matter disclosed herein involves, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of one or more systems and/or articles.
In some aspects, an electrochemical cell is provided.
In some embodiments, the electrochemical cell comprises an insulating layer having a first side and a second side; a cathode current collector directly adjacent to the insulating layer at the first side configured to be connected to a first terminal; an anode current collector directly adjacent to the insulating layer at the second side configured to be connected to a second terminal, wherein the insulating layer prevents electronic communication and ionic communication between the cathode current collector and the anode current collector; and a cathode electroactive material layer positioned adjacent the cathode current collector at a side opposite the insulating layer.
In some aspects, a method of forming an electrochemical cell is provided.
In some embodiments, the method comprises depositing a cathode current collector on a first side of an insulating layer; depositing an anode current collector on a second side of the insulating layer opposite the first side, wherein the insulating layer is configured to inhibit electronic communication and ionic communication between the cathode current collector and the anode current collector; and depositing a cathode electroactive material layer on the cathode current collector.
In some aspects, a method of electrical energy storage and use is provided.
In some embodiments, the method comprises: in an electrochemical cell comprising a first insulating layer having a first side and a second side; a first cathode current collector directly adjacent to the first insulating layer at the first side; a first anode current collector directly adjacent to the first insulating layer at the second side, wherein the first insulating layer prevents electronic communication and ionic communication between the first cathode current collector and the first anode current collector; a first cathode electroactive material layer positioned adjacent the first cathode current collector at a side opposite the first insulating layer; an electrolyte positioned adjacent the first anode current collector at a side opposite the first insulating layer; a second cathode electroactive material layer positioned adjacent the electrolyte at a side opposite the first anode current collector; and a second cathode current collector positioned adjacent the second cathode electroactive material layer at a side opposite the electrolyte; applying a voltage during at least one period of time during charge of the electrochemical cell; and forming a first anode electroactive material layer between the electrolyte and the first anode current collector.
Other advantages and novel features of the present invention will become apparent from the following detailed description of various non-limiting embodiments of the invention when considered in conjunction with the accompanying figures. In cases where the present specification and a document incorporated by reference include conflicting and/or inconsistent disclosure, the present specification shall control.
Non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying figures, which are schematic and are not intended to be drawn to scale unless otherwise indicated. In the figures, each identical or nearly identical component illustrated is typically represented by a single numeral. For purposes of clarity, not every component is labeled in every figure, nor is every component of each embodiment of the invention shown where illustration is not necessary to allow those of ordinary skill in the art to understand the invention. In the figures:
Articles and methods directed to electrochemical cells comprising integrated components are disclosed herein. The electrochemical cell may comprise cell units that may comprise, for example, an insulating layer, current collectors, electroactive material layers, separators, at least two, or all, of which components are integrated to one another. In some embodiments, the electrochemical cell includes at least an integrated electrode and separator. Such an electrochemical cell may exhibit enhanced performance properties compared to certain existing electrochemical cells that do not have these integrated features. For instance, the manufacturing of an electrochemical cell having integrated components and/or as a single integrated unit may reduce the complexity of cell assembly. Additionally, the integrated electrochemical cell may advantageously exhibit enhanced specific energy and energy density compared to certain existing electrochemical cells that do not have these integrated features. These advantages may be caused in part by a reduction in the overall weight and volume of non-electroactive materials in the cell. For example, the manufacturing method described herein may allow for the production of integrated electrochemical cells comprising thinner non-electroactive material layers (e.g., insulating layer, current collectors, etc.). Furthermore, the manufacturing methods described herein may advantageously allow for the simultaneous production of a plurality of integrated electrochemical cell units, thereby reducing the complexity of manufacturing.
Some aspects of the disclosure herein are also directed to an integrated “anode-free” electrochemical cell. An “anode-free” electrochemical cell may refer to an electrochemical cell that lacks an anode (i.e., anode electroactive material layer), e.g., prior to first charge of the cell. Such a cell configuration may allow for in situ formation of an anode electroactive material layer during charge, and may advantageously enhance safety of electrochemical cells during use. For example, the lack of an anode in the cell may be associated with an absence of lithium excess, such that less amount of heat may be generated in cases of thermal runaway. Such a cell configuration may also improve the safety of the cell during handling and/or storage of the cell. Methods of electrical storage and use of such an “anode-free” electrochemical cell are also disclosed herein.
Some embodiments are directed to an integrated electrochemical cell comprising current collectors, an insulating layer, and a cathode electroactive material layer (i.e., a cathode), and optional other components, as described in more detail below.
In some embodiments, the electrochemical cell comprises a cell unit comprising an insulating layer having a first side and a second side, a cathode current collector directly adjacent to the insulating layer at the first side, and an anode current collector directly adjacent to the insulating layer at the second side.
As used herein, when a layer is referred to as being “on”, “on top of”, or “adjacent” another layer, it can be directly on, on top of, or adjacent the layer, or an intervening layer may also be present. A layer that is “directly on”, “directly adjacent” or “in contact with” another layer means that no intervening layer is present. Likewise, a layer that is positioned “between” two layers may be directly between the two layers such that no intervening layer is present, or an intervening layer may be present.
In some embodiments, two or more components of the cell unit are integrated (or integrally connected) to one another. In some embodiments, each component of the cell unit are integrated (or integrally connected) to at least one other directly adjacent component. For example, as shown in
As used herein, two components are integrated (or integrally connected) to one another if the two components cannot be separated manually; e.g., separation requires at least the use of tools, and/or by causing damage to at least one of the components, for example, by breaking, peeling, or separating components fastened together via adhesives or tools. By contrast, two components that are merely collated (e.g., fabricated separately and then pressed against one another) would not be integrated or integrally connected to one another. For example, a commercially available separator positioned against a commercially-available anode electroactive layer (e.g., a lithium metal foil) would not be integrated (or integrally connected) to one another. In some embodiments, components that are integrated (or integrally connected) do not become separated from each other during the course of normal use, e.g., they may be irreversibly attached to one another during the course of normal use.
In some embodiments, the insulating layer described herein prevents electronic communication and ionic communication between the cathode current collector and the anode current collector. Advantageously, the presence of such an insulating layer can prevent shorts between the cathode current collector and anode current collector during cell cycling of the cell. As described in more detail below, the current collectors may comprise any of a variety of metals. The insulating material layer may comprise any of a variety of polymers having a relatively low electronic and ionic conductivity.
In some embodiments, the current collectors described herein are positioned such that each current collector is connected to a corresponding terminal. In some such embodiments, the cathode current collector is connected to a first terminal (e.g., a positive terminal) and the anode current collector is connected to a second terminal (e.g., a negative terminal). As shown in
In some embodiments, the positions of the cathode and anode current collectors are offset to each other by a certain distance, such that the current collectors can be connected to their corresponding terminals without interference from each other. For example, as shown in
In some embodiments, the electrochemical cell comprises a cell unit that further comprises a cathode electroactive material layer that is positioned adjacent the cathode current collector at a side opposite the insulating layer. As shown in
While
In some embodiments, additional layers may be present in the cell unit described herein. For example, in one set of embodiments, the electrochemical cell comprises a cell unit that further comprises an anode electroactive material layer comprising an anode electroactive material (e.g., lithium metal and/or lithium alloy). In some such embodiments, the electroactive material layer may be positioned adjacent the anode current collector at a side opposite the insulating layer.
In some embodiments, the anode electroactive material layer has a dimension (e.g., width) that is less than a dimension (e.g., width) of the anode current collector. As shown in
As noted above, additional layers may be present in the cell unit. Non-limiting examples of such layers include one or more separator layers, an ion conductive layer, a precursor layer, and a primer layer.
In some embodiments, one or more separators may be present in the cell unit described herein. In some embodiments, the one or more separators comprise porous separator materials that may contain a non-solid electrolyte. As used herein, a non-solid electrolyte may refer to materials that are unable to withstand a static shear stress, and when a shear stress is applied, the non-solid experiences a continuing and permanent distortion. Examples of non-solids include, for example, liquids, deformable gels, and the like.
In some embodiments in which one or more separators are present, the one or more separators may be disposed adjacent (e.g., directly adjacent) an anode electroactive material layer and/or a cathode electroactive material layer. For example, in one set of embodiments, the electrochemical cell described herein comprises a cell unit comprising a first separator (i.e., a cathode-side separator) adjacent a cathode electroactive material layer. Referring to
Alternatively or additionally, an electrochemical cell may comprise a cell unit comprising a separator (i.e., a second separator such as anode-side separator) adjacent an anode electroactive material layer. As shown in
In some embodiments, the first separator and/or second separator comprises pores filled with an electrolyte. Each of the separators may comprise any of a variety of materials described herein. The first separator and the second separator may be the same or different. In one set of embodiments, the first separator may comprise a material that is different from the second separator. For instance, the first separator may comprise ceramic materials, and the second separator may comprise polymeric materials. In another set of embodiments, the first separator may comprise the same material as the second separator. Furthermore, in embodiments in which the electrolyte is a solid electrolyte, the one or more separators (e.g., separator 32 and/or separator 24) may comprise any of a variety of solid electrolyte. For example, in one set of embodiments, the one or more separators may be a ceramic solid state electrolyte.
In some embodiments, the one or more separators may have a configuration that substantially encapsulates (e.g., encloses) one or more layers in the cell unit. For instance, as shown illustratively in
In embodiments in which a second separator is present, the second separator may substantially encapsulate (e.g., enclose) one or more layers in the cell unit. For instance, as shown in
In some embodiments, a primer layer may be disposed between the cathode current collector and the cathode electroactive material layer. The presence of a primer layer may advantageously facilitate adhesion and electrical contact of the cathode electroactive material layer to the cathode current collector. As shown in
In some embodiments, a precursor layer (e.g., electrode precursor layer) may be present in the cell unit (e.g., an “anode free” cell unit as described herein). For example, the precursor layer may be positioned adjacent the anode current collector in the cell unit. Advantageously, the presence of a precursor layer may assist with the formation and/or deposition of the anode electroactive material layer in the electrochemical cell. For example, in one set of embodiments, a precursor layer may comprise an electrode precursor material (e.g., a metal) that is capable of reacting or alloying with a lithium to form an anode electroactive material layer comprising lithium metal and/or lithium metal alloy.
As shown in
In some embodiments, the electrochemical cell may comprise a cell unit that further comprise an ion conductive layer. In some such embodiments, the ion conductive layer may be positioned adjacent the anode electroactive material layer. As shown in
The integrated electrochemical cells comprising one or more cell units described herein (e.g.,
The integrated electrochemical cell described herein may advantageously have a relatively high specific energy and energy density compared to electrochemical cells manufactured using certain existing methods. These advantages may be caused in part by a reduction in the thickness of non-electroactive material layers within the cell. As described in more detail below, the manufacturing methods described herein may allow for deposition of non-electroactive material layers (e.g., insulating layer, cathode current collector, anode current collector) having reduced thickness and weight.
While some embodiments are directed to an electrochemical cell comprising a cell unit (e.g., cell unit 100
The anode-free electrochemical cell may comprise an anode-free cell unit that further comprise one or more additional layers described above with respective to
The use of an integrated anode-free electrochemical cell comprising one or more anode-free cell units (i.e., cell units that lack anode electroactive material layer(s)) (e.g., as shown in
In some embodiments, a method of electrical energy storage and use related to an anode-free electrochemical cell is disclosed herein. In some such embodiments, as described in more detail below, an anode electroactive material layer may be formed in situ upon cycling (e.g., discharging) of the anode-free electrochemical cell.
Some aspects of the disclosure are directed to a method of electrical energy storage and use of an anode-free electrochemical cell comprising one or more anode-free cell units described herein. In some such embodiments, the anode-free electrochemical cell has the configuration of a winded anode-free cell unit or is a stack of at least two or more anode-free cell units. For example,
In
In some embodiments, an electrochemical cell comprises a first insulating layer having a first side and a second side, a first cathode current collector directly adjacent to the first insulating layer at the first side, and a first anode current collector directly adjacent to the first insulating layer at the second side. As shown in
In some embodiments, the electrochemical cell comprises a first cathode electroactive material layer positioned adjacent the first cathode current collector at a side opposite the first insulating layer. As shown, the electrochemical cell 300 comprises a first cathode electroactive material layer 18 positioned adjacent the first cathode current collector 14 at a side opposite the first insulating layer 12. As noted above, optional intervening layers (e.g., a first primer layer 22) may be present between the first cathode current collector 14 and the first cathode electroactive material layer 18.
In some embodiments, the electrochemical cell comprises an electrolyte positioned adjacent the first anode current collector at a side opposite the first insulating layer. As shown in
As shown in
While
As noted above, optional intervening layers (e.g., precursor layer and/or ion conductive layer) may be present between the first anode current collector and the electrolyte (or separators). As shown in
In some embodiments, the electrochemical cell comprises a second cathode electroactive material layer positioned adjacent the electrolyte at a side opposite the first anode current collector. As shown in
Some embodiments are directed to applying a voltage during at least one period of time during charge of the electrochemical cell. For example, as shown in
In some embodiments, a first anode electroactive material layer is formed between the electrolyte and the first anode current collector in the electrochemical cell when the electrochemical cell is in a charged state.
In some embodiments, forming the first anode electroactive material layer comprises transporting lithium from the second cathode electroactive material layer during charge of the cell. As shown in
In some embodiments, as noted above, the electrochemical cell may comprise a precursor layer that may assist with deposition and formation of an anode electroactive material layer during charge of the cell. As shown in
In one set of embodiments, as shown in
In some embodiments, upon discharge of the electrochemical cell, at least a portion of the lithium within the first anode electroactive material layer may be dissolved within the electrolyte and transported back to the second cathode electroactive material layer.
It should be noted that although
While
The electrochemical cell described herein (e.g., as shown in
Some embodiments are related to applying, during at least one period of time during charge and/or discharge of the electrochemical cells (e.g., first cell unit, second cell unit, etc.), an anisotropic force with a component normal to an electrode surface (e.g., an active surface) of at least one cell unit of the stacked electrochemical cell or the winded cell configuration. As mentioned above, application of such a force may reduce potentially deleterious phenomena associated with certain types of electrochemical cells (e.g., cells comprising lithium metal as an electrode active material) and improve utilization. For example, in some cases, applying an anisotropic force with a component normal to an active surface of an electrode of the electrochemical cell can reduce problems (such as surface roughening of the electrode and dendrite formation) while improving current density.
In some embodiments, a method of forming an integrated electrochemical cell comprising the one or more cell units is described herein. The cell units may be any of the cell units described in
In some embodiments, the method comprises depositing (e.g., coating) a cathode current collector on a first side of an insulating layer. As shown in
In some embodiments, depositing current collectors (e.g., cathode current collector and/or anode current collector) on the insulating layer comprises coating the insulating layer with current collector materials (e.g., metals). The coated insulating layer may be subsequently used as a substrate for deposition of electroactive materials (or any intervening layers such as primer layers). Advantageously, the use of such a coated insulating layer (e.g., metal-coated insulating layer) as the substrate for depositing electrodes (e.g., cathode and/or anode electroactive material layers) may be more cost effective compared to the use of certain existing materials (e.g., thick metal foils such as lithium metal foils) as the electrode material. In addition, the methods described herein may advantageously allow for formation of thinner layers of materials (e.g., current collectors), and thus result in cells having reduced volume and weight.
In some embodiments, the method comprises depositing (e.g., coating) a cathode electroactive material layer on the cathode current collector at a side opposite the insulating layer. As shown in
In some embodiments, an anode electroactive material layer may be further deposited (e.g., coated) onto the cell unit 10 described in
Additionally or alternatively, one or more optional layers such as the primer layer 22, the precursor layer 26, the ion conductive layer 30, separator layers 24 and 32, may be sequentially deposited in the order necessary to form the cell units illustrated in
Some aspects of the disclosure are directed to a method of forming a series of discrete and identical cell units described herein. The series of cell units may be a series of any of the cell units described in
In some embodiments, forming a series of discrete and identical cell units comprises separating (e.g., cutting) the interconnected cell units from each other. For instance, as shown in
Although
As noted above, the electrochemical cell may be a winded electrochemical cell. In some embodiments, the electrochemical cell may comprise a cell unit that comprises one or more layers that are brittle. In some such embodiments, the cell unit may be wound in a direction that maintains the one or more brittle layers adjacent to or at the neutral axis of the winded cell unit. For instance, materials (e.g., ceramic materials such as ones that may be used for the separator, ones that may be used for the ion conductive layer and/or cathode electroactive materials) that have a relatively higher tolerance to compression may be positioned toward the inner radius of the winded cell unit, and materials (e.g., polymeric materials such as ones that may be used for the separator and/or metallic lithium) that have a relatively higher tolerance to tension may be positioned toward the outer radius of the winded cell unit.
In some embodiments, the integrated electrochemical cell described herein may comprise certain components that provide the cell with enhanced safety properties during use. In some such embodiments, as mentioned above, the integrated electrochemical comprises a cell unit comprising an insulating layer coated with relatively thin layers of current collectors on each side (e.g., as shown in
Materials for the current collector may be selected, in some cases, from metals (e.g., copper, nickel, aluminum, passivated metals, and other appropriate metals), metallized polymers, electrically conductive polymers, polymers comprising conductive particles dispersed therein, and other appropriate materials. In some embodiments, the current collector material is deposited onto the insulating layer using vacuum deposition, physical vapor deposition, chemical vapor deposition, electrochemical deposition, sputtering, doctor blading, flash evaporation, or any other appropriate deposition technique for the selected material.
In some embodiments, the cathode current collector comprises an electron conductive material comprising one or more of Al, Ti, Ni, and carbon. In some embodiments, the anode current collector described herein comprises an electron conductive material comprising one or more of Cu, Ni, Mg, Zn, and carbon.
The cathode current collectors described herein may have any of a variety of appropriate thicknesses. In some embodiments, the cathode current collectors described herein may have a smaller thickness compared to cathode current collectors fabricated via conventional manufacturing processes. In some embodiments, a cathode current collector may have a thickness of greater than or equal to 0.1 microns, greater than or equal to 0.2 microns, greater than or equal to 0.4 microns, greater than or equal to 0.6 microns, greater than or equal to 0.8 microns, greater than or equal to 1 micron, greater than or equal to 1.5 microns, greater than or equal to 2.0 microns, greater than or equal to 2.5 microns, greater than or equal to 3 microns, greater than or equal to 3.5 microns, greater than or equal to 4 microns, greater than or equal to 4.5 microns, greater than or equal to 5 microns, greater than or equal to 6 microns, or greater than or equal to 7.5 microns. In some embodiments, a cathode current collector may have a thickness of less than or equal to 10 microns, less than or equal to 7.5 microns, less than or equal to 6 microns, less than or equal to 5 microns, less than or equal to 4.5 microns, less than or equal to 4 microns, less than or equal to 3.5 microns, less than or equal to 3 microns, less than or equal to 2.5 microns, less than or equal to 2 microns, less than or equal to 1.5 microns, less than or equal to 1 micron, less than or equal to 0.8 microns, less than or equal to 0.6 microns, less than or equal to 0.4 microns, less than or equal to 0.2 microns, or less than or equal to 0.1 microns. Combination of the above-referenced ranges are possible (e.g., greater than or equal to 0.1 microns and less than or equal to 10 microns, or greater than or equal to 0.2 microns and less than or equal to 5 microns, or greater than or equal to 0.2 microns and less than or equal to 1 micron). Other ranges are also possible.
The anode current collectors described herein may have any of a variety of appropriate thicknesses. In some embodiments, the anode current collectors described herein may have a smaller thickness compared to anode current collectors fabricated via conventional manufacturing processes. In some embodiments, an anode current collector may have a thickness of greater than or equal to 0.01 microns, greater than or equal to 0.025 microns, greater than or equal to 0.05 microns, greater than or equal to 0.1 microns, greater than or equal to 0.2 microns, greater than or equal to 0.4 microns, greater than or equal to 0.6 microns, greater than or equal to 0.8 microns, greater than or equal to 1 micron, greater than or equal to 1.5 microns, greater than or equal to 2.0 microns, greater than or equal to 2.5 microns, greater than or equal to 3 microns, greater than or equal to 3.5 microns, greater than or equal to 4 microns, greater than or equal to 4.5 microns, greater than or equal to 5 microns, or greater than or equal to 7.5 microns. In some embodiments, an anode current collector may have a thickness of less than or equal to 10 microns, less than or equal to 7.5 microns, less than or equal to 5 microns, less than or equal to 4.5 microns, less than or equal to 4 microns, less than or equal to 3.5 microns, less than or equal to 3 microns, less than or equal to 2.5 microns, less than or equal to 2 microns, less than or equal to 1.5 microns, less than or equal to 1 micron, less than or equal to 0.8 microns, less than or equal to 0.6 microns, less than or equal to 0.4 microns, less than or equal to 0.2 microns, less than or equal to 0.1 microns, less than or equal to 0.05 microns, or less than or equal to 0.025 microns. Combination of the above-referenced ranges are possible (e.g., greater than or equal to 0.01 microns and less than or equal to 10 microns, greater than or equal to 0.01 microns and less than or equal to 5 microns, greater than or equal to 0.2 microns and less than or equal to 5 microns, greater than or equal to 0.01 microns and less than or equal to 1 micron, or greater than or equal to 0.2 microns and less than or equal to 1 micron). Other ranges are also possible.
As mentioned above, the current collectors (e.g., cathode current collector 14 and/or anode current collector 16 as shown in
The current collectors described herein (e.g., cathode current collector 14 and/or anode current collector 16 as shown in
The insulating layer described herein may have any of a variety of appropriate thicknesses. In some embodiments, the insulating layer described herein may have a relatively small thickness. In some embodiments, an insulating layer may have a thickness of greater than or equal to 0.1 microns, greater than or equal to 0.25 microns, greater than or equal to 0.5 microns, greater than or equal to 1 micron, greater than or equal to 1.5 microns, greater than or equal to 2 microns, greater than or equal to 2.5 microns, greater than or equal to 3 microns, greater than or equal to 3.5 microns, greater than or equal to 4 microns, greater than or equal to 5 microns, greater than or equal to 6 microns, greater than or equal to 8 microns, greater than or equal to 10 microns, greater than or equal to 15 microns, greater than or equal to 20 microns, greater than or equal to 25 microns, greater than or equal to 30 microns, greater than or equal to 35 microns, greater than or equal to 40 microns, or greater than or equal to 45 microns. In some embodiments, an insulating layer may have a thickness of less than or equal to 50 microns, less than or equal to 45 microns, less than or equal to 40 microns, less than or equal to 35 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 15 microns, less than or equal to 10 microns, less than or equal to 8 microns, less than or equal to 6 microns, less than or equal to 4 microns, less than or equal to 3.5 microns, less than or equal to 3 microns, less than or equal to 2.5 microns, less than or equal to 2 microns, less than or equal to 1.5 microns, less than or equal to 1 micron, less than or equal to 0.5 microns, or less than or equal to 0.25 microns. Combination of the above-referenced ranges are possible (e.g., greater than or equal to 0.1 microns and less than or equal to 50 microns, greater than or equal to 4 microns and less than or equal to 50 microns, greater than or equal to 0.1 microns and less than or equal to 10 microns, or greater than or equal to 0.1 microns and less than or equal to 4 microns). Other ranges are also possible.
The insulating layer may have any of a variety of appropriate widths. In some embodiments, the insulating layer has a width w12 that is greater any of the widths of any of the adjacent layers and components (e.g., as shown in
The insulating layer may comprise any of a variety of insulating materials (e.g., polymers) having both a low electronic conductivity and ionic conductivity. Non-limiting examples of insulating polymers include, but are not limited to polyethylene terephthalate, polyester, polyimide, polysulfone, polyurethane, derivatives or combination thereof. Additional examples include any appropriate polymers having a low electronic conductivity and ionic conductivity. For instance, the polymer may have an ionic conductivity and/or electronic conductivity each of which may be independently less than or equal to 10−6 S/cm (e.g., less than or equal to 10−8 S/cm, less than or equal to 10−10 S/cm, less than or equal to 10−12 S/cm, less than or equal to 10−14 S/cm, or less than or equal to 10−16 S/cm, less than or equal to 10−18 S/cm, or less than or equal to less than or equal to 10−20 S/cm).
A cathode electroactive material layer described herein may have any of a variety of appropriate thicknesses. In some embodiments, a cathode electroactive material layer may have a thickness of greater than or equal to 1 micron, greater than or equal to 2 microns, greater than or equal to 3 microns, greater than or equal to 5 microns, greater than or equal to 10 microns, greater than or equal to 15 microns greater than or equal to 20 microns, greater than or equal to 25 microns, greater than or equal to 30 microns, greater than or equal to 35 microns, greater than or equal to 40 microns, greater than or equal to 45 microns, greater than or equal to 50 microns, greater than or equal to 55 microns, or greater than or equal to 60 microns. In some embodiments, a cathode electroactive material layer may have a thickness of less than or equal to 70 microns less than or equal to 60 microns, less than or equal to 55 microns, less than or equal to 50 microns, less than or equal to 45 microns, less than or equal to 40 microns, less than or equal to 35 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 15 microns, less than or equal to 10 microns, less than or equal to 5 microns, less than or equal to 3 microns, or less than or equal to 2 microns. Combination of the above-referenced ranges are possible (e.g., greater than or equal to 1 micron and less than or equal to 60 microns, greater than or equal to 20 microns and less than or equal to 60 microns, greater than or equal to 1 micron and less than or equal to 20 microns, or greater than or equal to 1 micron and less than or equal to 10 microns). Other ranges are also possible.
The cathode electroactive material layer may have any of a variety of appropriate widths. In some embodiments, the cathode electroactive material layer may have a width that is less than the width of the anode current collector. Additionally, the cathode electroactive material layer may be positioned such that it offsets from the edges of the anode current collector. Such a configuration may advantageously allow for mitigation of excessive and non-uniform lithium buildup at the edges of the anode electrochemical material layer during charge.
As noted above, the cathode electroactive material layer comprises a cathode electroactive material. A variety of cathode active materials are suitable for use with cathodes of the electrochemical cells described herein, according to certain embodiments. In some embodiments, the cathode active material comprises a lithium intercalation compound (e.g., a compound that is capable of reversibly inserting lithium ions at lattice sites and/or interstitial sites). In certain cases, the cathode active material comprises a layered oxide. A layered oxide generally refers to an oxide having a lamellar structure (e.g., a plurality of sheets, or layers, stacked upon each other). Non-limiting examples of suitable layered oxides include lithium cobalt oxide (LiCoO2), lithium nickel oxide (LiNiO2), and lithium manganese oxide (LiMnO2). In some embodiments, the layered oxide is lithium nickel manganese cobalt oxide (LiNixMnyCozO2, also referred to as “NMC” or “NCM”). In some such embodiments, the sum of x, y, and z is 1. For example, a non-limiting example of a suitable NMC compound is LiNi1/3Mn1/3Co1/3O2. In some embodiments, a layered oxide may have the formula (Li2MnO3)x(LiMO2)(1−x) where M is one or more of Ni, Mn, and Co. For example, the layered oxide may be (Li2MnO3)0.25(LiNi0.3Co0.15Mn0.55O2)0.75. In some embodiments, the layered oxide is lithium nickel cobalt aluminum oxide (LiNixCoyAlzO2, also referred to as “NCA”). In some such embodiments, the sum of x, y, and z is 1. For example, a non-limiting example of a suitable NCA compound is LiNi0.8Co0.15Al0.05O2. In certain embodiments, the cathode active material is a transition metal polyanion oxide (e.g., a compound comprising a transition metal, an oxygen, and/or an anion having a charge with an absolute value greater than 1). A non-limiting example of a suitable transition metal polyanion oxide is lithium iron phosphate (LiFePO4, also referred to as “LFP”). Another non-limiting example of a suitable transition metal polyanion oxide is lithium manganese iron phosphate (LiMnxFe1−xPO4, also referred to as “LMFP”). A non-limiting example of a suitable LMFP compound is LiMn0.8Fe0.2PO4. In some embodiments, the cathode active material is a spinel (e.g., a compound having the structure AB2O4, where A can be Li, Mg, Fe, Mn, Zn, Cu, Ni, Ti, or Si, and B can be Al, Fe, Cr, Mn, or V). A non-limiting example of a suitable spinel is a lithium manganese oxide with the chemical formula LiMxMn2−xO4 where M is one or more of Co, Mg, Cr, Ni, Fe, Ti, and Zn. In some embodiments, x may equal 0 and the spinel may be lithium manganese oxide (LiMn2O4, also referred to as “LMO”). Another non-limiting example is lithium manganese nickel oxide (LiNixM2−xO4, also referred to as “LMNO”). A non-limiting example of a suitable LMNO compound is LiNi0.5Mn1.5O4. In certain cases, the electroactive material of the second electrode comprises Li1.14Mn0.42Ni0.25Co0.29O2 (“HC-MNC”), lithium carbonate (Li2CO3), lithium carbides (e.g., Li2C2, Li4C, Li6C2, Li8C3, Li6C3, Li4C3, Li4C5), vanadium oxides (e.g., V2O5, V2O3, V6O13), and/or vanadium phosphates (e.g., lithium vanadium phosphates, such as Li3V2(PO4)3), or any combination thereof.
In some embodiments, the cathode active material comprises a conversion compound. For instance, the cathode may be a lithium conversion cathode. It has been recognized that a cathode comprising a conversion compound may have a relatively large specific capacity. Without wishing to be bound by a particular theory, a relatively large specific capacity may be achieved by utilizing all possible oxidation states of a compound through a conversion reaction in which more than one electron transfer takes place per transition metal (e.g., compared to 0.1-1 electron transfer in intercalation compounds). Suitable conversion compounds include, but are not limited to, transition metal oxides (e.g., Co3O4), transition metal hydrides, transition metal sulfides, transition metal nitrides, and transition metal fluorides (e.g., CuF2, FeF2, FeF3). A transition metal generally refers to an element whose atom has a partially filled d sub-shell (e.g., Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, Rf, Db, Sg, Bh, Hs).
In some cases, the cathode active material may be doped with one or more dopants to alter the electrical properties (e.g., electrical conductivity) of the cathode active material. Non-limiting examples of suitable dopants include aluminum, niobium, silver, and zirconium.
The cathode active material may be modified by a surface coating comprising an oxide. Non-limiting examples of surface oxide coating materials include: MgO, Al2O3, SiO2, TiO2, ZnO2, SnO2, and ZrO2. Such coatings may prevent direct contact between the cathode active material and the electrolyte, thereby suppressing side reactions.
In certain embodiments, the cathode active material comprises sulfur. In some embodiments, the cathode active material comprises electroactive sulfur-containing materials. “Electroactive sulfur-containing materials,” as used herein, refers to electrode active materials which comprise the element sulfur in any form, wherein the electrochemical activity involves the oxidation or reduction of sulfur atoms or moieties. As an example, the electroactive sulfur-containing material may comprise elemental sulfur (e.g., S8). In some embodiments, the electroactive sulfur-containing material comprises a mixture of elemental sulfur and a sulfur-containing polymer. Thus, suitable electroactive sulfur-containing materials may include, but are not limited to, elemental sulfur, sulfides or polysulfides (e.g., of alkali metals) which may be organic or inorganic, and organic materials comprising sulfur atoms and carbon atoms, which may or may not be polymeric. Suitable organic materials include, but are not limited to, those further comprising heteroatoms, conductive polymer segments, composites, and conductive polymers. In some embodiments, an electroactive sulfur-containing material within an electrode (e.g., a cathode) comprises at least 40 wt % sulfur. In some cases, the electroactive sulfur-containing material comprises at least 50 wt %, at least 75 wt %, or at least 90 wt % sulfur.
Examples of sulfur-containing polymers include those described in: U.S. Pat. Nos. 5,601,947 and 5,690,702 to Skotheim et al.; U.S. Pat. Nos. 5,529,860 and 6,117,590 to Skotheim et al.; U.S. Pat. No. 6,201,100 issued Mar. 13, 2001, to Gorkovenko et al., and PCT Publication No. WO 99/33130, each of which is incorporated herein by reference in its entirety for all purposes. Other suitable electroactive sulfur-containing materials comprising polysulfide linkages are described in U.S. Pat. No. 5,441,831 to Skotheim et al.; U.S. Pat. No. 4,664,991 to Perichaud et al., and in U.S. Pat. Nos. 5,723,230, 5,783,330, 5,792,575 and 5,882,819 to Naoi et al., each of which is incorporated herein by reference in its entirety for all purposes. Still further examples of electroactive sulfur-containing materials include those comprising disulfide groups as described, for example in, U.S. Pat. No. 4,739,018 to Armand et al.; U.S. Pat. Nos. 4,833,048 and 4,917,974, both to De Jonghe et al.; U.S. Pat. Nos. 5,162,175 and 5,516,598, both to Visco et al.; and U.S. Pat. No. 5,324,599 to Oyama et al., each of which is incorporated herein by reference in its entirety for all purposes.
One or more electrodes may further comprise additional additives, such as conductive additives, binders, etc., as described in U.S. Pat. No. 9,034,421 to Mikhaylik et al.; and U.S. Patent Application Publication No. 2013/0316072, each of which is incorporated herein by reference in its entirety for all purposes.
An anode electroactive material layer described herein may have any of a variety of appropriate thicknesses. In some embodiments, an anode electroactive material layer may have a thickness of greater than or equal to 0 microns, greater than or equal to 1 micron, greater than or equal to 2 microns, greater than or equal to 3 microns, greater than or equal to 5 microns, greater than or equal to 10 microns, greater than or equal to 15 microns greater than or equal to 20 microns, greater than or equal to 25 microns, greater than or equal to 30 microns, greater than or equal to 35 microns, greater than or equal to 40 microns, greater than or equal to 45 microns, greater than or equal to 50 microns, greater than or equal to 55 microns, or greater than or equal to 60 microns. In some embodiments, an anode electroactive material layer may have a thickness of less than or equal to 70 microns less than or equal to 60 microns, less than or equal to 55 microns, less than or equal to 50 microns, less than or equal to 45 microns, less than or equal to 40 microns, less than or equal to 35 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 15 microns, less than or equal to 10 microns, less than or equal to 5 microns, less than or equal to 3 microns, less than or equal to 2 microns, or less than or equal to 1 micron. Combination of the above-referenced ranges are possible (e.g., greater than or equal to 0 microns and less than or equal to 60 microns, greater than or equal to 1 micron and less than or equal to 60 microns, greater than or equal to 20 microns and less than or equal to 60 microns, or greater than or equal to 0 micron and less than or equal to 20 microns). Other ranges are also possible.
The anode electroactive material layer may have any of a variety of appropriate widths w20 (e.g., as shown in
As noted above, the anode electroactive material layer comprises an anode electroactive (i.e., active) material. As used herein, the term “anode active material” refers to any electrochemically active species associated with the anode. For example, the anode may comprise a lithium-containing material, wherein lithium is the anode active material. A variety of anode active materials are suitable for use with the anodes of the electrochemical cells described herein, according to certain embodiments. In some embodiments, the anode active material comprises lithium (e.g., lithium metal), such as lithium foil, lithium deposited onto a conductive substrate or onto a non-conductive substrate (e.g., a release layer), and lithium alloys (e.g., lithium-aluminum alloys and lithium-tin alloys). Lithium can be contained as one film or as several films, optionally separated. Suitable lithium alloys for use in the aspects described herein can include alloys of lithium and aluminum, magnesium, silicium (silicon), indium, and/or tin. In some embodiments, the anode active material comprises lithium (e.g., lithium metal and/or a lithium metal alloy) during at least a portion of or during all of a charging and/or discharging process of the electrochemical cell. In some embodiments, the anode active material comprises lithium during a portion of a charging and/or discharging process of the electrochemical cell, but is free of lithium metal and/or a lithium metal alloy at a completion of a discharging process.
In some embodiments, the anode active material contains at least 50 wt % lithium. In some cases, the anode active material contains at least 75 wt %, at least 90 wt %, at least 95 wt %, or at least 99 wt % lithium. In some embodiments, the lithium may be in the form of lithium metal.
In some embodiments, the anode is an electrode from which lithium ions are liberated during discharge and into which the lithium ions are integrated (e.g., intercalated) during charge. In some embodiments, the anode active material is a lithium intercalation compound (e.g., a compound that is capable of reversibly inserting lithium ions at lattice sites and/or interstitial sites). In some embodiments, the anode active material comprises carbon. In certain cases, the anode active material is or comprises a graphitic material (e.g., graphite). A graphitic material generally refers to a material that comprises a plurality of layers of graphene (i.e., layers comprising carbon atoms covalently bonded in a hexagonal lattice). Adjacent graphene layers are typically attracted to each other via van der Waals forces, although covalent bonds may be present between one or more sheets in some cases. In some cases, the carbon-comprising anode active material is or comprises coke (e.g., petroleum coke). In certain embodiments, the anode active material comprises silicon, lithium, and/or any alloys of combinations thereof. In certain embodiments, the anode active material comprises lithium titanate (Li4Ti5O12, also referred to as “LTO”), tin-cobalt oxide, or any combinations thereof.
Methods for depositing an anode electroactive material layer or a negative electrode material (e.g., an alkali metal anode such as lithium) onto a substrate may include methods such as vacuum deposition, thermal evaporation, sputtering, jet vapor deposition, and laser ablation. Alternatively, where the anode comprises a lithium foil, or a lithium foil and a substrate, these can be laminated together by a lamination process as known in the art to form an anode.
The one or more separators described herein may have any of a variety of appropriate thicknesses. In embodiments in which a first separator (e.g., a cathode-side separator 24 as shown in
As described herein, in some embodiments, an electrochemical cell includes a separator. The separator generally comprises a polymeric material (e.g., polymeric material that does or does not swell upon exposure to electrolyte). In some embodiments, the separator is located between the electrolyte and an electrode (e.g., between the electrolyte and a first electrode, between the electrolyte and a second electrode, between the electrolyte and an anode, or between the electrolyte and a cathode).
In some embodiments, electrochemical cells may further comprise a separator interposed between the cathode and anode. The separator may be a solid non-conductive or insulative material which separates or insulates the anode and the cathode from each other preventing short circuiting, and which permits the transport of ions between the anode and the cathode. In some embodiments, the porous separator may be permeable to the electrolyte.
The pores of the separator may be partially or substantially filled with electrolyte. Separators may be supplied as porous free standing films which are interleaved with the anodes and the cathodes during the fabrication of cells. Alternatively, the porous separator layer may be applied directly to the surface of one of the electrodes, for example, as described in PCT Publication No. WO 99/33125 to Carlson et al. and in U.S. Pat. No. 5,194,341 to Bagley et al.
A separator can be made of a variety of materials. The separator may be polymeric in some instances, or formed of an inorganic material (e.g., glass fiber filter papers) in other instances. Examples of suitable separator materials include, but are not limited to, polyolefins (e.g., polyethylenes, poly(butene-1), poly(n-pentene-2), polypropylene, polytetrafluoroethylene), polyamines (e.g., poly(ethylene imine) and polypropylene imine (PPI)); polyamides (e.g., polyamide (Nylon), poly(e-caprolactam) (Nylon 6), poly(hexamethylene adipamide) (Nylon 66)), polyimides (e.g., polyimide, polynitrile, and poly(pyromellitimide-1,4-diphenyl ether) (Kapton®) (NOMEX®) (KEVLAR®)); polyether ether ketone (PEEK); vinyl polymers (e.g., polyacrylamide, poly(2-vinyl pyridine), poly(N-vinylpyrrolidone), poly(methylcyanoacrylate), poly(ethylcyanoacrylate), poly(butylcyanoacrylate), poly(isobutylcyanoacrylate), poly(vinyl acetate), poly(vinyl alcohol), poly(vinyl chloride), poly(vinyl fluoride), poly(2-vinyl pyridine), vinyl polymer, polychlorotrifluoro ethylene, and poly(isohexylcynaoacrylate)); polyacetals; polyesters (e.g., polycarbonate, polybutylene terephthalate, polyhydroxybutyrate); polyethers (poly(ethylene oxide) (PEO), poly(propylene oxide) (PPO), poly(tetramethylene oxide) (PTMO)); vinylidene polymers (e.g., polyisobutylene, poly(methyl styrene), poly(methylmethacrylate) (PMMA), poly(vinylidene chloride), and poly(vinylidene fluoride)); polyaramides (e.g., poly(imino-1,3-phenylene iminoisophthaloyl) and poly(imino-1,4-phenylene iminoterephthaloyl)); polyheteroaromatic compounds (e.g., polybenzimidazole (PBI), polybenzobisoxazole (PBO) and polybenzobisthiazole (PBT)); polyheterocyclic compounds (e.g., polypyrrole); polyurethanes; phenolic polymers (e.g., phenol-formaldehyde); polyalkynes (e.g., polyacetylene); polydienes (e.g., 1,2-polybutadiene, cis or trans-1,4-polybutadiene); polysiloxanes (e.g., poly(dimethylsiloxane) (PDMS), poly(diethylsiloxane) (PDES), polydiphenylsiloxane (PDPS), and polymethylphenylsiloxane (PMPS)); and inorganic polymers (e.g., polyphosphazene, polyphosphonate, polysilanes, polysilazanes). In some embodiments, the polymer may be selected from poly(n-pentene-2), polypropylene, polytetrafluoroethylene, polyamides (e.g., polyamide (Nylon), poly(e-caprolactam) (Nylon 6), poly(hexamethylene adipamide) (Nylon 66)), polyimides (e.g., polynitrile, and poly(pyromellitimide-1,4-diphenyl ether) (Kapton®) (NOMEX®) (KEVLAR®)), polyether ether ketone (PEEK), and combinations thereof.
A separator can be coated by various materials (e.g. ceramics). In some embodiments, a separator is a ceramic coated separator. Non-limiting examples of ceramic include alumina, boehmite, and/or silica. In some embodiments, a separator comprising a polymeric material described previously (e.g., polyolefin) may be coated by a ceramic described herein.
A variety of separator materials are known in the art. Examples of suitable solid porous separator materials include, but are not limited to, polyolefins, such as, for example, polyethylenes (e.g., SETELA™ made by Tonen Chemical Corp) and polypropylenes, glass fiber filter papers, and ceramic materials. For example, in some embodiments, the separator comprises a microporous polyethylene film. Further examples of separators and separator materials suitable for use in this invention are those comprising a microporous xerogel layer, for example, a microporous pseudo-boehmite layer, which may be provided either as a free standing film or by a direct coating application on one of the electrodes, as described in U.S. Pat. Nos. 6,153,337 and 6,306,545 by Carlson et al. of the common assignee.
Solid electrolytes and gel electrolytes may also function as a separator in addition to their electrolyte function. In some embodiments, one or more solid polymers can be used to form an electrolyte. Examples of useful solid polymer electrolytes include, but are not limited to, those comprising one or more polymers selected from the group consisting of polyethers, polyethylene oxides, polypropylene oxides, polyimides, polyphosphazenes, polyacrylonitriles, polysiloxanes, derivatives of the foregoing, copolymers of the foregoing, crosslinked and network structures of the foregoing, and blends of the foregoing.
Liquid electrolyte solvents can also be useful as plasticizers for gel polymer electrolytes, i.e., electrolytes comprising one or more polymers forming a semi-solid network. Examples of useful gel polymer electrolytes include, but are not limited to, those comprising one or more polymers selected from the group consisting of polyethylene oxides, polypropylene oxides, polyacrylonitriles, polysiloxanes, polyimides, polyphosphazenes, polyethers, sulfonated polyimides, perfluorinated membranes (NAFION resins), polydivinyl polyethylene glycols, polyethylene glycol diacrylates, polyethylene glycol dimethacrylates, polysulfones, polyethersulfones, derivatives of the foregoing, copolymers of the foregoing, crosslinked and network structures of the foregoing, and blends of the foregoing, and optionally, one or more plasticizers. In some embodiments, a gel polymer electrolyte comprises between 10-20%, between 20-40%, between 60-70%, between 70-80%, between 80-90%, or between 90-95% of a heterogeneous electrolyte by volume.
In addition to electrolyte solvents, gelling agents, and polymers as known in the art for forming electrolytes, the electrolyte may further comprise one or more ionic electrolyte salts, also as known in the art, to increase the ionic conductivity.
A primer layer may comprise any of a variety of appropriate materials described herein. For example, in one set of embodiments, a primer layer comprises binders and/or electronically conductive additives.
A primer layer may have any of a variety of appropriate dimensions (e.g., thickness and/or width). For instance, as shown in
In some embodiments, a precursor layer comprises a metal. In other cases, a precursor layer comprises a semiconductor. For example, in one set of embodiments, a precursor comprises one or more metals selected from one or more of Sn, Pb, intermetallic compounds, transition metal nitrides, transition metal oxides, transition metal sulfides, and transition metal halogenides. In some embodiments, the precursor layer can form an alloy with lithium metal. Additional materials that may be suitable for use in a precursor layer include, for example, a Group 1-17 element, a Group 2-14 element, or a Group 2, 10, 11, 12, 13, 14, 15 element. Suitable elements from Group 2 of the Periodic Table may include beryllium, magnesium, calcium, strontium, and barium. Suitable elements from Group 10 may include, for example, nickel, palladium, or platinum. Suitable elements from Group 11 may include, for example, copper, silver, or gold. Suitable elements from Group 12 may include, for example, zinc, cadmium, or mercury. Elements from Group 13 that may be used in the present invention may include, for example, boron, aluminum, gallium, indium, or thallium. Elements from Group 14 that may be used in the present invention may include, for example, carbon, silicon, germanium, tin, or lead. Elements from Group 15 that may be used in the present invention may include, for example, nitrogen, phosphorus, or bismuth. In some cases, the precursor layer comprises Al, Mg, Zn, or Si.
Where a precursor layer comprises a metal, it is to be understood that one or more metals can be used. Similarly, where a precursor layer comprises a semiconductor, one or more semiconducting materials can be used. Additionally, metals and semiconductors can be mixed. That is, a precursor layer can be a single metal, a single semiconductor, or one or more metals or one or more semiconductors mixed. Non-limiting examples of suitable metals are listed above, and suitable components of semiconductors are listed above. Those of ordinary skill in the art are well aware of semiconductors that can be formed from one or more of the elements listed above, or other elements.
In some cases, where a precursor layer is present and alloys with lithium, the alloying material (which may include a material suitable for use in a precursor layer) may be present in the electroactive layer in an amount greater than 25 ppm, 50 ppm, 100 ppm, 200 ppm, 300 ppm, 400 ppm or 500 ppm, but less than or equal to 1 wt %, 2 wt %, 5 wt %, 10 wt %, 12 wt %, 15 wt %, or 20 wt % of the electroactive layer. As used herein, “wt % of the electroactive layer” means percent by total weight of the electroactive layer itself, absent current collector, protective structure, electrolyte and other materials.
It should be appreciated that in some embodiments, a precursor layer may be present in an electrode or an electrochemical cell, but does not alloy with the electroactive material during formation and/or use of the electrode or cell. In other embodiments, the precursor layer may be designed to intercalate ions of the electroactive material. Non-limiting examples of suitable materials that may intercalate ions of an electroactive material (e.g., alkaline metal ions) include carbon (e.g., graphite), titanium sulfide, and iron sulfide. In some cases, a precursor layer comprises silicon and/or germanium.
In other embodiments, a precursor layer includes a layer of lithium. The use of a lithium layer positioned between the current collector and the protective structure may be used as a seed layer to facilitate the formation of an electroactive layer. For instance, under certain conditions, the use of an intervening lithium layer can result in the formation of a smooth electroactive lithium layer. It should be appreciated that in such embodiments, the precursor layer, although it may comprise lithium, is not used as an electroactive layer itself. For instance, the thickness of the precursor layer may be such that it is unsuitable for use as an electroactive layer, but is suitable for use in an electrode or electrochemical cell assembled in a discharged state (e.g., as a seed layer). In some such embodiments, for example, the precursor layer is present in an amount such that the material participates in less than 100%, less than 80%, less than 60%, less than 40%, less than 20%, less than 10%, less than 5%, less than 2%, or less than 1% of a full discharge of the electrochemical cell.
As noted above, lithium transported from a cathode electroactive material layer may react with a metal from the precursor layer to form an anode electroactive material layer. In some embodiments, lithium may intercalate with the precursor material in the precursor layer, thus converting the precursor layer into an anode electroactive material layer. In one set of embodiments, an electrochemically active electrode precursor may be provided, comprising a carbon-based electrically-conductive material and an active electrode species. For example, the electrode precursor may include a porous carbon substrate and an active electrode species within the substrate. Material may be removed from the electrode precursor essentially uniformly to form the electrode. As used herein, removing material “essentially uniformly” from the electrode precursor means that material is removed uniformly throughout the bulk of the electrode precursor.
A precursor layer may have any of a variety of appropriate dimensions (e.g., thickness and/or width). For instance, as shown in
The precursor layer positioned adjacent the current collector may have any of a variety of appropriate thicknesses. For instance, the thickness of the precursor layer may be less than 5 microns, less than or equal to 4.5 microns, less than or equal to 4 microns, less than or equal to 3.5 microns, less than or equal to 2 microns, less than or equal to 2.5 microns, less than or equal to 2 microns, less than 1.8 microns, less than or equal to 1.5 microns, less than or equal to 1 micron, less than or equal to 800 nm, less than or equal to 600 nm, less than or equal to 400 nm, less than or equal to 300 nm, less than or equal to 200 nm, less than or equal to 100 nm, less than or equal to 50 nm, less than or equal to 40 nm, less than or equal to 30 nm, less than or equal to 20 nm, less than or equal to 10 nm, or less than or equal to 5 nm. In some embodiments, the thickness of the precursor layer may be greater than or equal to 5 nm, greater than or equal to 10 nm, greater than or equal to 20 nm, greater than or equal to 30 nm, greater than or equal to 40 nm, greater than or equal to 50 nm, greater than or equal to 100 nm, greater than or equal to 200 nm, greater than or equal to 300 nm, greater than or equal to 400 nm, greater than or equal to 600 nm, greater than or equal to 800 nm, greater than or equal to 1 micron, greater than or equal to 1.5 microns, greater than or equal to 2 microns, greater than or equal to 2.5 microns, greater than or equal to 3 microns, greater than or equal to 3.5 microns, greater than or equal to 4 microns, or greater than or equal to 4.5 microns. Combinations of the above-referenced ranges are also possible (greater than or equal to 1 nm and less than or equal to 5 microns, or greater than or equal to 1 nm and less than or equal to 2 microns). Other ranges of thicknesses are also possible.
In one set of embodiments, the ion conductive layer (e.g., single-ion conductive layer) may have a shape or structure that protects the anode electroactive material layer from one or more undesirable components (within the electrolyte) within the electrochemical cell. In some such embodiments, the anode electroactive material layer may be at least partially encapsulated by the ion conductive layer. As shown in
The ion conductive layer described herein may have any of a variety of appropriate thicknesses. In some embodiments, an ion conductive layer (e.g., 30 as shown in
The ion conductive layer may have any of a variety of appropriate widths. In some embodiments, as shown in
In some embodiments, the ion conductive layer may be formed by any of a variety of appropriate methods and comprise any of a variety of appropriate materials. Some methods relate to forming an ion conductive layer by an aerosol deposition process. Aerosol deposition processes are known in the art and generally comprise depositing (e.g., spraying) particles (e.g., inorganic particles, polymeric particles) at a relatively high velocity on a surface. Aerosol deposition, as described herein, generally results in the collision and/or elastic deformation of at least some of the plurality of particles. In some aspects, aerosol deposition can be carried out under conditions (e.g., using a velocity) sufficient to cause fusion of at least some of the plurality of particles to at least another portion of the plurality of particles. For example, in some embodiments, a plurality of particles is deposited on an electroactive material (and/or any sublayer(s) disposed thereon) at a relative high velocity such that at least a portion of the plurality of particles fuse (e.g., forming the portion and/or sublayer of the protective layer). The velocity required for particle fusion may depend on factors such as the material composition of the particles, the size of the particles, the Young's elastic modulus of the particles, and/or the yield strength of the particles or material forming the particles.
In some embodiments, an ion conductive layer described herein comprises an inorganic material. The inorganic material(s) may comprise a ceramic material (e.g., a glass, a glassy-ceramic material). The inorganic material(s) may be crystalline, amorphous, or partially crystalline and partially amorphous. In some embodiments, the ion conductive layer comprises LixMPySz. For such inorganic materials, x, y, and z may be integers (e.g., integers less than 32) and/or M may comprise Sn, Ge, and/or Si. By way of example, the inorganic material may comprise Li22SiP2S18, Li24MP2S19 (e.g., Li24SiP2S19), LiMP2S12 (e.g., where M=Sn, Ge, Si), and/or LiSiPS. Even further examples of suitable inorganic materials include garnets, sulfides, phosphates, perovskites, anti-perovskites, other ion conductive inorganic materials and/or mixtures thereof. When LixMPySz particles are employed in an ion conductive layer thereof, they may be formed, for example, by using raw components Li2S, SiS2 and P2S5 (or alternatively Li2S, Si, S and P2S5).
In some embodiments, an ion conductive layer described herein comprises an oxide, nitride, and/or oxynitride of lithium, aluminum, silicon, zinc, tin, vanadium, zirconium, magnesium, and/or indium, and/or an alloy thereof. Non-limiting examples of suitable oxides include Li2O, LiO, LiO2, LiRO2 where R is a rare earth metal (e.g., lithium lanthanum oxides), lithium titanium oxides, Al2O3, ZrO2, SiO2, CeO2, and Al2TiO5. Further examples of suitable materials that may be employed include lithium nitrates (e.g., LiNO3), lithium silicates, lithium borates (e.g., lithium bis(oxalate)borate, lithium difluoro(oxalate)borate), lithium aluminates, lithium oxalates, lithium phosphates (e.g., LiPO3, Li3PO4), lithium phosphorus oxynitrides, lithium silicosulfides, lithium germanosulfides, lithium fluorides (e.g., LiF, LiBF4, LiAlF4, LiPF6, LiAsF6, LiSbF6, Li2SiF6, LiSO3F, LiN(SO2F)2, LiN(SO2CF3)2), lithium borosulfides, lithium aluminosulfides, lithium phosphosulfides, oxy-sulfides (e.g., lithium oxy-sulfides), and/or combinations thereof. In some embodiments, the plurality of particles comprises Li—Al—Ti—PO4 (LATP).
In some embodiments, an ion conductive layer described herein comprises a plurality of particles that are at least partially fused together and/or that have a structure indicative of particles deposited by aerosol deposition comprises an inorganic material. For instance, a plurality of particles that are at least partially fused together and/or that have a structure indicative of particles deposited by aerosol deposition may be formed of an inorganic material. In some embodiments, a plurality of particles that are at least partially fused together and/or that have a structure indicative of particles deposited by aerosol deposition comprise two or more types of inorganic materials. The plurality of particles may comprise any appropriate materials described above.
In some embodiments, an ion conductive layer described herein may comprise pores with an average size (e.g., an average size that is advantageous) of greater than or equal to 10 nm, greater than or equal to 15 nm, greater than or equal to 20 nm, greater than or equal to 30 nm, greater than or equal to 50 nm, greater than or equal to 75 nm, greater than or equal to 100 nm, greater than or equal to 150 nm, greater than or equal to 200 nm, greater than or equal to 300 nm, greater than or equal to 500 nm, or greater than or equal to 750 nm. The average pore size of the ion conductive layer may be less than or equal to 1 micron, less than or equal to 750 nm, less than or equal to 500 nm, less than or equal to 300 nm, less than or equal to 200 nm, less than or equal to 150 nm, less than or equal to 100 nm, less than or equal to 75 nm, less than or equal to 50 nm, less than or equal to 30 nm, less than or equal to 20 nm, or less than or equal to 15 nm. Combinations of the above-referenced ranges are also possible (e.g., greater than or equal to 10 nm and less than or equal to 1 micron). Other ranges are also possible. When more than one ion conductive layer is present, each ion conductive layer may independently comprise pores with an average size in one or more of the ranges above. In some embodiments, a protective layer and/or sublayer thereof comprises a polymer with an average pore size in one or more of the ranges listed above. BET surface analysis, as described, for example, in S. Brunauer, P. H. Emmett, and E. Teller, J. Am. Chem. Soc., 1938, 60, 309, which is incorporated herein by reference in its entirety, may be used to determine the average pore size of the ion conductive layer.
The electrochemical cells described herein may comprise an electrolyte. The electrolyte can function as a medium for the storage and transport of ions, and in the special case of solid electrolytes and gel electrolytes, these materials may additionally function as a separator between an anode and a cathode. Any liquid, solid, or gel material capable of storing and transporting ions may be used, so long as the material facilitates the transport of ions (e.g., lithium ions) between an anode and the cathode. The electrolyte is electronically non-conductive to prevent short circuiting between an anode and a cathode. In some embodiments, the electrolyte may comprise a non-solid electrolyte.
In some embodiments, the electrolyte comprises a fluid that can be added at any point in the fabrication process. In some cases, the electrochemical cell may be fabricated by providing a cathode and an anode, applying an anisotropic force component normal to the active surface of the anode, and subsequently adding the fluid electrolyte such that the electrolyte is in electrochemical communication with the cathode and the anode. In other cases, the fluid electrolyte may be added to the electrochemical cell prior to or simultaneously with the application of an anisotropic force component, after which the electrolyte is in electrochemical communication with the cathode and the anode.
The electrolyte can comprise one or more ionic electrolyte salts to provide ionic conductivity and one or more liquid electrolyte solvents, gel polymer materials, or polymer materials. Suitable non-aqueous electrolytes may include organic electrolytes comprising one or more materials selected from the group consisting of liquid electrolytes, gel polymer electrolytes, and solid polymer electrolytes. Examples of non-aqueous electrolytes for lithium batteries are described by Dorniney in Lithium Batteries, New Materials, Developments and Perspectives, Chapter 4, pp. 137-165, Elsevier, Amsterdam (1994). Examples of gel polymer electrolytes and solid polymer electrolytes are described by Alamgir et al. in Lithium Batteries, New Materials, Developments and Perspectives, Chapter 3, pp. 93-136, Elsevier, Amsterdam (1994). Heterogeneous electrolyte compositions that can be used in batteries described herein are described in U.S. patent application Ser. No. 12/312,764, filed May 26, 2009 and entitled “Separation of Electrolytes,” by Mikhaylik et al., which is incorporated herein by reference in its entirety.
Examples of useful non-aqueous liquid electrolyte solvents include, but are not limited to, non-aqueous organic solvents, such as, for example, N-methyl acetamide, acetonitrile, acetals, ketals, esters, carbonates, sulfones, sulfites, sulfolanes, aliphatic ethers, cyclic ethers, glymes, polyethers, phosphate esters, siloxanes, dioxolanes, N-alkylpyrrolidones, substituted forms of the foregoing, and blends thereof. Fluorinated derivatives of the foregoing are also useful as liquid electrolyte solvents.
In some cases, aqueous solvents can be used as electrolytes, for example, in lithium cells. Aqueous solvents can include water, which can contain other components such as ionic salts. As noted above, in some embodiments, the electrolyte can include species such as lithium hydroxide, or other species rendering the electrolyte basic, so as to reduce the concentration of hydrogen ions in the electrolyte.
In one set of embodiments, the solvent comprises at least one fluorinated organic solvent. In some embodiments, a fluorinated organic solvent and/or a mixture of fluorinated organic solvent is used as the sole solvent in the electrolyte. In some embodiments, the at least one fluorinated organic solvent is selected from group of cyclic and linear fluorinated carbonates, fluorinated ethers, and fluorinated esters (e.g., fluorinated alkyl esters). For example, in one embodiment, the solvent comprises at least one fluorinated organic solvent that is selected from fluoroethylene carbonate and/or difluoroethylene carbonate. Additional non-limiting examples of fluorinated organic solvent include, but are not limited to, methyl, 2,2,2,-trifluoroethyl carbonate, 1,1,2,2,-tetrafluoroethyl 2,2,2-trifluoroethylether, 1,1,2,2-tetrafluoroethyl-2,2,3,3-tetrafluoropropylether, methyl difluoroacetate, ethyl difluoroacetate, methyl trifluoroacetate, and ethyl trifluoroacetate.
In some embodiments, the solvent further comprises at least one non-fluorinated organic solvent. In some embodiments, the at least one non-fluorinated organic solvent comprises ester-based solvents. In some embodiments, the organic solvent may comprise one or more of esters of carboxylic acids, esters of phosphoric acid, linear and cyclic ethers and acetals, esters of sulfuric acids, esters of sulfonic acids, esters formed from carboxylic acids and halogenated alcohols, and alkyl esters. In some embodiments, the at least one non-fluorinated organic solvent comprises cyclic and/or linear carbonates. In some such embodiments, the non-fluorinated solvent may comprise one or more of carbonate-based solvents selected from the group of dimethyl carbonate, diethyl carbonate, ethyl methyl carbonate, propylene carbonate, and ethylene carbonate. Additionally or alternatively, the at least one non-fluorinated organic solvent may comprise acetates (e.g., methyl acetate, ethyl acetate), alky esters (e.g, ethyl butyrate), lactones (e.g., gamma-butyrolactone), etc.
In some embodiments, the organic solvent may comprise one or more of carbonate-based solvents selected from the group of fluoroethylene carbonate, dimethyl carbonate, diethyl carbonate, ethyl methyl carbonate, propylene carbonate, and ethylene carbonate. In some embodiments, the organic solvent may comprise a mixture of fluoroethylene carbonate and dimethyl carbonate. In some embodiments, a weight ratio of fluoroethylene carbonate and dimethyl carbonate may be greater than or equal to 1:10 and less than or equal to 100:1. In some embodiments, the weight ratio is greater than or equal to 1:4 and less than or equal to 1:3. Other ranges may be possible.
In some embodiments, the electrolyte comprises at least one lithium salt. In one set of embodiments, the lithium salt may comprise one or more of lithium hexafluorophosphate (LiPF6), lithium bis(fluorosulfonyl)imide (LiFSI), lithium perchlorate (LiClO4), lithium hexafluoroarsenate (LiAsF6), lithium tetrafluoroborate (LiBF4), lithium trifluromethanesulfonate (LiCF3SO3), and lithium bis(trifluoromethanesulfonyl)imide (LiTFSI). Additional examples of lithium include, but are not limited to, LiSCN, LiBr, LiI, LiSO3CH3, LiNO3, LiPF6, LiBF4, LiB(Ph)4, LiClO4, LiAsF6, Li2SiF6, LiSbF6, LiAlCl4, lithium bis(oxalato)borate, lithium difluoro(oxalato)borate, a salt comprising a tris(oxalato)phosphate anion (e.g., lithium tris(oxalato)phosphate), LiC(SO2CF3)3, LiCF3SO3, LiN(SO2F)2, LiN(SO2CF3)2, LiC(CnF2n+1SO2)3 wherein n is an integer in the range of from 1 to 20, and (CnF2n+1SO2)mXLi with n being an integer in the range of from 1 to 20, m being 1 when X is selected from oxygen or sulfur, m being 2 when X is selected from nitrogen or phosphorus, and m being 3 when X is selected from carbon or silicon. Other electrolyte salts that may be useful include lithium polysulfides (Li2Sx), and lithium salts of organic polysulfides (LiSxR)n, where x is an integer from 1 to 20, n is an integer from 1 to 3, and R is an organic group, and those disclosed in U.S. Pat. No. 5,538,812 to Lee et al., which is incorporated herein by reference in its entirety for all purposes.
When present, a lithium salt may be present in the electrolyte at a variety of suitable concentrations. In some embodiments, the lithium salt is present in the electrolyte at a concentration of greater than or equal to 0.01 M, greater than or equal to 0.02 M, greater than or equal to 0.05 M, greater than or equal to 0.1 M, greater than or equal to 0.2 M, greater than or equal to 0.5 M, greater than or equal to 1 M, greater than or equal to 2 M, or greater than or equal to 5 M. The lithium salt may be present in the electrolyte at a concentration of less than or equal to 10 M, less than or equal to 5 M, less than or equal to 2 M, less than or equal to 1 M, less than or equal to 0.5 M, less than or equal to 0.2 M, less than or equal to 0.1 M, less than or equal to 0.05 M, or less than or equal to 0.02 M. Combinations of the above-referenced ranges are also possible (e.g., greater than or equal to 0.01 M and less than or equal to 10 M, or greater than or equal to 0.01 M and less than or equal to 5 M). Other ranges are also possible.
In some embodiments, the electrolyte comprises one or more room temperature ionic liquids. The room temperature ionic liquid, if present, typically comprises one or more cations and one or more anions. Non-limiting examples of suitable cations include lithium cations and/or one or more quaternary ammonium cations such as imidazolium, pyrrolidinium, pyridinium, tetraalkylammonium, pyrazolium, piperidinium, pyridazinium, pyrimidinium, pyrazinium, oxazolium, and trizolium cations. Non-limiting examples of suitable anions include trifluromethylsulfonate (CF3SO3−), bis (fluorosulfonyl)imide (N(FSO2)2−, bis (trifluoromethyl sulfonyl)imide ((CF3SO2)2N−, bis (perfluoroethylsulfonyl)imide((CF3CF2SO2)2N− and tris(trifluoromethylsulfonyl)methide ((CF3SO2)3C−. Non-limiting examples of suitable ionic liquids include N-methyl-N-propylpyrrolidinium/bis(fluorosulfonyl) imide and 1,2-dimethyl-3-propylimidazolium/bis(trifluoromethanesulfonyl)imide. In some embodiments, the electrolyte comprises both a room temperature ionic liquid and a lithium salt. In some other embodiments, the electrolyte comprises a room temperature ionic liquid and does not include a lithium salt.
As described above, in some embodiments, a force, or forces, is applied to portions of an electrochemical cell. Such application of force may reduce irregularity or roughening of an electrode surface of the cell (e.g., when lithium metal or lithium alloy anodes are employed), thereby improving performance. Electrochemical devices in which anisotropic forces are applied and methods for applying such forces are described, for example, in U.S. Pat. No. 9,105,938, issued Aug. 11, 2015, published as U.S. Patent Publication No. 2010/0035128 on Feb. 11, 2010, and entitled “Application of Force in Electrochemical Cells,” which is incorporated herein by reference in its entirety for all purposes.
In the embodiments described herein, batteries may undergo a charge/discharge cycle involving deposition of metal (e.g., lithium metal or other active material) on a surface of an anode upon charging and reaction of the metal on the anode surface, wherein the metal diffuses from the anode surface, upon discharging. The uniformity with which the metal is deposited on the anode may affect cell performance. For example, when lithium metal is removed from and/or redeposited on an anode, it may, in some cases, result in an uneven surface. For example, upon redeposition it may deposit unevenly forming a rough surface. The roughened surface may increase the amount of lithium metal available for undesired chemical reactions which may result in decreased cycling lifetime and/or poor cell performance. The application of force to the electrochemical device has been found, in accordance with certain embodiments described herein, to reduce such behavior and to improve the cycling lifetime and/or performance of the cell.
In some embodiments, the battery (e.g., a housing of the battery) is configured to apply, during at least one period of time during charge and/or discharge of the device, an anisotropic force with a component normal to an electrode active surface of one of the electrochemical cells (e.g., first electrochemical cell, second electrochemical cell).
In some embodiments, an anisotropic force with a component normal to an electrode active surface of one of the electrochemical cells (e.g., first electrochemical cell, second electrochemical cell) is applied during at least one period of time during charge and/or discharge of the battery. In some embodiments, the force is applied continuously, over one period of time, or over multiple periods of time that may vary in duration and/or frequency. The anisotropic force may be applied, in some cases, at one or more pre-determined locations, optionally distributed over an active surface of the one or more of the electrochemical cells of the battery. In some embodiments, the anisotropic force is applied uniformly over one or more active surfaces of the anode.
An “anisotropic force” is given its ordinary meaning in the art and means a force that is not equal in all directions. A force equal in all directions is, for example, internal pressure of a fluid or material within the fluid or material, such as internal gas pressure of an object. Examples of forces not equal in all directions include forces directed in a particular direction, such as the force on a table applied by an object on the table via gravity. Another example of an anisotropic force includes certain forces applied by a band arranged around a perimeter of an object. For example, a rubber band or turnbuckle can apply forces around a perimeter of an object around which it is wrapped. However, the band may not apply any direct force on any part of the exterior surface of the object not in contact with the band. In addition, when the band is expanded along a first axis to a greater extent than a second axis, the band can apply a larger force in the direction parallel to the first axis than the force applied parallel to the second axis.
A force with a “component normal” to a surface, for example an active surface of an electrode such as an anode, is given its ordinary meaning as would be understood by those of ordinary skill in the art and includes, for example, a force which, at least in part, exerts itself in a direction substantially perpendicular to the surface. Those of ordinary skill can understand other examples of these terms, especially as applied within the description of this document.
In some embodiments, the anisotropic force can be applied such that the magnitude of the force is substantially equal in all directions within a plane defining a cross-section of the battery, but the magnitude of the forces in out-of-plane directions is substantially unequal to the magnitudes of the in-plane forces.
In one set of embodiments, batteries (e.g., housings) described herein are configured to apply, during at least one period of time during charge and/or discharge of the cell, an anisotropic force with a component normal to an electrode active surface of one of the electrochemical cells (e.g., first electrochemical cell, second electrochemical cell). Those of ordinary skill in the art will understand the meaning of this. In such an arrangement, the electrochemical cell may be formed as part of a container which applies such a force by virtue of a “load” applied during or after assembly of the cell, or applied during use of the battery as a result of expansion and/or contraction of one or more components of the battery itself.
The magnitude of the applied force is, in some embodiments, large enough to enhance the performance of the battery. An electrode active surface (e.g., anode active surface) and the anisotropic force may be, in some instances, together selected such that the anisotropic force affects surface morphology of the electrode active surface to inhibit increase in electrode active surface area through charge and discharge and wherein, in the absence of the anisotropic force but under otherwise essentially identical conditions, the electrode active surface area is increased to a greater extent through charge and discharge cycles. “Essentially identical conditions,” in this context, means conditions that are similar or identical other than the application and/or magnitude of the force. For example, otherwise identical conditions may mean a battery that is identical, but where it is not constructed (e.g., by couplings such as brackets or other connections) to apply the anisotropic force on the subject battery.
As described herein, in some embodiments, the surface of an anode can be enhanced during cycling (e.g., for lithium, the development of mossy or a rough surface of lithium may be reduced or eliminated) by application of an externally-applied (in some embodiments, uniaxial) pressure. The externally-applied pressure may, in some embodiments, be chosen to be greater than the yield stress of a material forming the anode. For example, for an anode comprising lithium, the cell may be under an externally-applied anisotropic force with a component defining a pressure of at least 10 kgf/cm2, at least 20 kgf/cm2, or more. This is because the yield stress of lithium is around 7-8 kgf/cm2. Thus, at pressures (e.g., uniaxial pressures) greater than this value, mossy Li, or any surface roughness at all, may be reduced or suppressed. The lithium surface roughness may mimic the surface that is pressing against it. Accordingly, when cycling under at least about 10 kgf/cm2, at least about 20 kgf/cm2, and/or up 30 kgf/cm2, up to 40 kgf/cm2 of externally-applied pressure, the lithium surface may become smoother with cycling when the pressing surface is smooth.
In some cases, one or more forces applied to the cell have a component that is not normal to an active surface of an anode. For example, in
In some cases, electrochemical cells may be pre-compressed before they are inserted into housings, and, upon being inserted to the house, they may expand to produce a net force on the electrochemical cells. Such an arrangement may be advantageous, for example, if the electrochemical cells are capable of withstanding relatively high variations in pressure.
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While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present invention. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described and claimed. The present invention is directed to each individual feature, system, article, material, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, and/or methods, if such features, systems, articles, materials, and/or methods are not mutually inconsistent, is included within the scope of the present invention.
The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”
The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified unless clearly indicated to the contrary. Thus, as a non-limiting example, a reference to “A and/or B,” when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A without B (optionally including elements other than B); in another embodiment, to B without A (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.
As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.
As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.
Some embodiments may be embodied as a method, of which various examples have been described. The acts performed as part of the methods may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include different (e.g., more or less) acts than those that are described, and/or that may involve performing some acts simultaneously, even though the acts are shown as being performed sequentially in the embodiments specifically described above.
Use of ordinal terms such as “first,” “second,” “third,” etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.
In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.
This application claims priority to U.S. Provisional Application No. 63/182,654, filed Apr. 30, 2021, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63182654 | Apr 2021 | US |
