This invention relates generally to electrolytes for lithium batteries, and, more specifically, to electrolytes that are especially suited for use in cathodes and at high voltages.
More and more lithium battery manufacturers are using next-generation cathode materials such as NCA (lithium nickel cobalt aluminum oxide), NCM (lithium nickel cobalt manganese oxide), and high energy NCM (HE-NCM-magnesium-rich lithium nickel cobalt manganese oxide) in order to exploit their potentially high gravimetric energy densities (as high as 300-500 Wh/kg), their good rate capabilities, and their long-term stability. Cells made with such oxidic cathode materials often operate at higher voltages (e.g., as high as 4.7V) than do cells (e.g., 3.6-3.8V) with olivine cathode materials such as LFP (lithium iron phosphate). Electrolytes that have been stable at the lower voltages of LFP cells may have difficulty operating at the higher voltages, especially in the cathode. Degradation, in the form of oxidation, may lead to capacity fade early in the life of a cell.
Thus, there is a need to develop electrolytes that are especially well-suited to operate in the high voltage conditions of next generation cathode materials.
In one embodiment of the invention, a polymer is disclosed. The polymer is a poly(pyrocarbonate)-based polymer structure described by:
In some embodiments of the invention, any of the polymers described herein are combined with an electrolyte salt and can be used as a polymer electrolyte.
In some embodiments of the invention, any of the polymer electrolytes described herein further includes ceramic electrolyte particles.
In some arrangements, any of the polymers described herein is crosslinked. In some arrangements any of the polymers described herein is crosslinked and is combined with an electrolyte salt to be used as a polymer electrolyte.
In one embodiment of the invention, a positive electrode includes a positive electrode active material; and a catholyte comprising any of the electrolytes described herein. The positive electrode active material particles and the catholyte are mixed together. The catholyte may also include a solid polymer electrolyte. The catholyte may also include ceramic electrolyte particles. The catholyte may be crosslinked. The catholyte may contain an electrolyte salt that is a lithium salt.
The positive electrode active material may be any of lithium iron phosphate, lithium metal phosphate, divanadium pentoxide, lithium nickel cobalt aluminum oxide, lithium nickel cobalt manganese oxide, magnesium-rich lithium nickel cobalt manganese oxide, lithium manganese spinel, lithium nickel manganese spinel, and combinations thereof.
In another embodiment of the invention an electrochemical cell includes an anode configured to absorb and release lithium ions; a cathode comprising cathode active material particles, an electronically-conductive additive, and a first catholyte; a current collector adjacent to an outside surface of the cathode; and a separator region between the anode and the cathode, the separator region comprising a separator electrolyte configured to facilitate movement of lithium ions back and forth between the anode and the cathode. The first catholyte may include any of the electrolytes described herein. The first catholyte may also contain ceramic electrolyte particles. The first catholyte may be crosslinked. The electrolyte salt may be a lithium salt.
The first catholyte and/or the separator electrolyte may also contain a solid polymer electrolyte. In one arrangement, the first catholyte and the separator electrolyte are the same.
In one arrangement, there is an overcoat layer between the cathode and the separator region. The overcoat layer includes a second catholyte, which may be any of the electrolytes disclosed herein. The first catholyte and the second catholyte may or may not be the same.
The anode may contain any of lithium metal, lithium alloy, lithium titanate, graphite and silicon.
The foregoing aspects and others will be readily appreciated by the skilled artisan from the following description of illustrative embodiments when read in conjunction with the accompanying drawings.
The embodiments of the invention are illustrated in the context of pyrocarbonate polymers that can be used as electrolytes or electrolyte additives in lithium battery cells and the like. The skilled artisan will readily appreciate, however, that the materials and methods disclosed herein will have application in a number of other contexts where high-voltage electrolytes are desirable, particularly where long-term stability is important.
These and other objects and advantages of the present invention will become more fully apparent from the following description taken in conjunction with the accompanying drawings.
All publications referred to herein are incorporated by reference in their entirety for all purposes as if fully set forth herein.
In this disclosure, the terms “negative electrode” and “anode” are both used to describe a negative electrode. Likewise, the terms “positive electrode” and “cathode” are both used to describe a positive electrode.
It is to be understood that the terms “lithium metal” or “lithium foil,” as used herein with respect to negative electrodes, describe both pure lithium metal and lithium-rich metal alloys as are known in the art. Examples of lithium rich metal alloys suitable for use as anodes include Li—Al, Li—Si, Li—Sn, Li—Hg, Li—Zn, Li—Pb, Li—C or any other Li-metal alloy suitable for use in lithium metal batteries. Other negative electrode materials that can be used in the embodiments of the invention include materials in which lithium can intercalate, such as graphite, and other materials that can absorb and release lithium ions, such as silicon, germanium, tin, and alloys thereof. Many embodiments described herein are directed to batteries with solid polymer electrolytes, which serve the functions of both electrolyte and separator. As it is well known in the art, batteries with liquid electrolytes use an inactive separator material that is distinct from the liquid electrolyte.
The following construction is used throughout this disclosure: “each variable is chosen independently” from a list that is provided. An example of this usage can be found with reference to X groups in some of the inventive polymer structures in which there are many Xs. The example is, “each X may be chosen independently from hydrogen, fluorine, methyl, ethyl, isopropyl, and trifluoromethyl groups.” This construction is used to mean that for a particular X in the structure, any of the groups in the list may be used. In choosing a group to use for another X in the structure, any of the groups in the list may be used with no regard to the choices that have been made for other X groups. Thus, the following arrangements are all possible: all the Xs may be the same, all the Xs may be different, or some Xs may be the same and some may be different.
The molecular weights given herein are number-averaged molecular weights.
The term “solid polymer electrolyte” is used herein to mean a polymer electrolyte that is solid at battery cell operating temperatures. Examples of useful battery cell operating temperatures include room temperature (25° C.), 40° C., and 80° C.
In this disclosure, ranges of values are given for many variables. It should be understood that the possible values for any variable also include any range subsumed within the given range.
Based on repeated observation of Li+ interaction with other atoms in molecular dynamics (MD) simulations, it seems that Li+ coordinates with partially-negatively-charged atoms in polymer electrolytes. For example, in polyethylene oxide (PEO), Li+ coordinates with partially-negatively-charged oxygen atoms in the PEO. Similarly, in poly(pyrocarbonate)s, Li+ coordinates with partially-negatively charged oxygens of the carbonyl groups.
In some embodiments of the invention, the general structures of poly(pyrocarbonate) and atomic variations thereof are shown in structures A and B below. For structure A, when Y is oxygen (O), the molecule is poly(pyrocarbonate). For structure A, when Y is sulphur (S), the molecule is poly(thiopyrocarbonate). Structure B shows the general structure for poly(imidopyrocarbonate), a carbamate-based polymer that has functional side chains Z that can be attached either directly as shown or through extendable alkyl chains (not shown).
Both a and n are integers. The value of a ranges from 1-10. The value of n ranges from 1 to 1000. Each R, Y, and Z is chosen independently from the lists below.
For Z, b is an integer that ranges from 1 to 10, and R1 may be chosen independently from hydrogen, methyl, ethyl, propyl, or isopropyl.
For R, c, d, and e are integers that each range independently from 0 to 10, and each X may be chosen independently from hydrogen, fluorine, methyl, ethyl, isopropyl, and trifluoromethyl.
Alternatively, one Structure C can be used to describe both Structures A and B, as shown below.
In Structure C, Q may be oxygen (O) or sulfur (S), as in Structure A, or nitrogen functionalized with Z (N—Z), as in Structure B. All integer (a, b, c, d, e, and n) values and options for R, X, Z, and R1 are as described above in reference to Structures A and B.
In another embodiment of the invention, particles of ceramic electrolyte are mixed into a poly(pyrocarbonate)-based polymer electrolyte to form an enhanced composite electrolyte with superior ionic transport and mechanical properties. Such a composite electrolyte may be used in a lithium battery cell in the separator region or in the cathode. Examples of ceramic electrolytes that are useful for mixing with poly(pyrocarbonate)-based electrolytes include, but are not limited to, those shown in Table 1 below.
Table 2 below shows simulated lithium ion transport properties for various poly(pyrocarbonate) materials. These polymers show excellent lithium ion transport properties. Specifically, the poly(pentylpyrocarbonate) is a promising candidate for lithium ion transport applications.
Cyclic voltammetry was measured using a three-electrode system that included a Pt button working electrode, a Pt wire counter electrode, and a quasi-reference electrode constructed from an Ag wire dipped in a 10 mM AgNO3 in 0.1 M tetrabutylammonium hexafluorophosphate solution in glass tubing with an attached Vycor frit. The quasi-reference electrode was first calibrated against a 10 mM ferrocene solution in 0.1 M lithium tetrafluoroborate (LiBF4) in propylene carbonate, to give Eox (ferrocene/ferrocenium)=0.058 V (vs. Ag/Ag+). Then the same ferrocene solution was used to calibrate a lithium reference electrode (Eox (ferrocene/ferrocenium)=3.35−3.39 V (vs. Li/Li+)). The cyclic voltammetry was carried out on 0.1M solution of diallyl pyrocarbonate in 0.1M LiBF4 in propylene carbonate and at a scan rate of 5 mV/s. The cyclic voltammetry data were then standardized for Li/Li+ to reflect oxidation stability in a lithium cell, as electrolyte materials made from acetyl acetone can interact with lithium electrodes in an actual battery cell. The results are shown in the graph in
Cell Designs that Include Poly(Pyrocarbonate)-Based Polymers
In one embodiment of the invention, a lithium battery cell 200 has an anode 220 that is configured to absorb and release lithium ions, as shown in
In another embodiment of the invention, a lithium battery cell 300 has an anode 320 that is configured to absorb and release lithium ions as shown in
In another embodiment of the invention, a battery cell with a third configuration is described. With reference to
A solid polymer electrolyte for use in separator region, such as separator regions 360 or 460, can be any electrolyte that is appropriate for use in a Li battery. Of course, many such electrolytes also include electrolyte salt(s) that help to provide ionic conductivity. Examples of such electrolytes include, but are not limited to, block copolymers that contain ionically-conductive blocks and structural blocks that make up ionically-conductive phases and structural phases, respectively. The ionically-conductive phase may contain one or more linear polymers such as polyethers, polyamines, polyimides, polyamides, poly alkyl carbonates, polynitriles, perfluoro polyethers, fluorocarbon polymers substituted with high dielectric constant groups such as nitriles, carbonates, and sulfones, and combinations thereof. In one arrangement, the ionically-conductive phase contains one or more poly(pyrocarbonate)-based polymer, as disclosed herein. The linear polymers can also be used in combination as graft copolymers with polysiloxanes, polyalkoxysiloxanes, polyphosphazines, polyolefins, and/or polydienes to form the conductive phase. The structural phase can be made of polymers such as polystyrene, hydrogenated polystyrene, polymethacrylate, poly(methyl methacrylate), polyvinylpyridine, polyvinylcyclohexane, polyimide, polyamide, polypropylene, polyolefins, poly(t-butyl vinyl ether), poly(cyclohexyl methacrylate), poly(cyclohexyl vinyl ether), poly(t-butyl vinyl ether), polyethylene, poly(phenylene oxide), poly(2,6-dimethyl-1,4-phenylene oxide), poly(phenylene sulfide), poly(phenylene sulfide sulfone), poly(phenylene sulfide ketone), poly(phenylene sulfide amide), polysulfone, fluorocarbons, such as polyvinylidene fluoride, or copolymers that contain styrene, methacrylate, or vinylpyridine. It is especially useful if the structural phase is rigid and is in a glassy or crystalline state.
With respect to the embodiments described in
Any of the polymers described herein may be liquid or solid, depending on its molecular weight. Any of the polymers described herein may be in a crosslinked or an uncrosslinked state. Any of the polymers described herein may be crystalline or glassy. Any of the polymers described herein may be copolymerized with other polymers to form copolymers, block copolymers, or graft copolymers. Copolymerization may also affect the mechanical properties of some polymers allowing them to become solid polymer electrolytes. Any of the polymers described herein can be combined with an electrolyte salt to be used as a solid polymer electrolyte. Any of these solid polymer electrolytes may be used as separator, catholyte, anolyte, or any combination thereof in a battery cell.
The following example provides details relating to synthesis of poly(pyrocarbonate)-based polymers in accordance with the present invention. It should be understood the following is representative only, and that the invention is not limited by the detail set forth in this example.
A synthetic route using acyclic diene metathesis (ADMET) to produce poly(pyrocarbonate), specifically poly(butenoicpyrocarbonate), is shown below. Hoveyda-Grubb's second-generation catalyst (0.03 g, 0.05 mmol) was added to a sample of diallyl pyrocarbonate (1.0 g, 5.3 mmol) and placed in high vacuum (˜1 torr). Bubbling of the reaction mixture was seen due to evolution of ethylene gas. The solution was slowly heated to 60° C. and stirred under high vacuum for 16 hours. After that, the reactor was back-filled with argon, the polymerization was quenched using a solution of ethyl vinyl ether (0.2 g, 2.5 mmol) in toluene (1 mL), and the polymer solution was stirred for half an hour. Slow addition of the polymer solution to petroleum ether (100 mL) yielded poly(butenoicpyrocarbonate) as an amber-colored waxy solid, which was then dried under high vacuum to obtain 0.3 g of dry polymer in 35% yield. Mw (GPC)=2,000 g/mol.
This invention has been described herein in considerable detail to provide those skilled in the art with information relevant to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by different equipment, materials and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself.
This application is a Continuation of International Patent Application PCT/US18/39603, filed Jun. 26, 2018, which is incorporated by reference herein.
Number | Date | Country | |
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Parent | PCT/US18/39603 | Jun 2018 | US |
Child | 16024464 | US |