SECONDARY BATTERY WITH IMPROVED BATTERY SEPARATOR
20230238652 · 2023-07-27
Inventors
Cpc classification
H01M4/505
ELECTRICITY
H01M4/131
ELECTRICITY
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M50/403
ELECTRICITY
H01M4/525
ELECTRICITY
H01M4/58
ELECTRICITY
H01M10/0525
ELECTRICITY
H01M50/451
ELECTRICITY
H01M50/414
ELECTRICITY
International classification
H01M50/451
ELECTRICITY
H01M50/403
ELECTRICITY
H01M4/58
ELECTRICITY
H01M4/525
ELECTRICITY
H01M4/505
ELECTRICITY
H01M50/414
ELECTRICITY
Abstract
A secondary battery that generates or includes metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, aluminum ions, chrome ions, molybdenum ions, tin ions or combinations thereof, the battery comprising: an anode; a cathode; a coated or uncoated battery separator between the anode and the cathode, wherein the coated or uncoated battery separator comprises a trap layer; and an electrolyte. The battery improve yield rate of initial charge and aging process and exhibits prolonged useful life due to the separator, which reduces or eliminates metal-ion contamination in the battery.
Claims
1. A secondary battery that generates or comprises metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, chrome or Cr ions, molybdenum ions, tin ions or combinations thereof, the battery comprising: an anode; a cathode; a coated or uncoated battery separator between the anode and the cathode, wherein the coated or uncoated battery separator comprises a trap layer; and an electrolyte.
2. The battery of claim 1, wherein the battery separator is a coated battery separator with a coating on an anode-facing side and the coating comprises a trap layer.
3. The battery of claim 1, wherein the trap layer has a potential difference vs. Li+/Li that is in the range of +0.0V to +5.0V.
4. The battery of claim 3, wherein the potential difference is +0.0 to +3.39 V or is +0.0 to +3.0 V.
5. The battery of claim 2, wherein the trap layer has a bulk or volume resistivity of 10.sup.4 to 10.sup.9 ohms-cm or 10.sup.4 to 10.sup.8 ohms-cm.
6. The battery of claim 5, wherein the trap layer has a bulk or volume resistivity of 10.sup.4 to 10.sup.7 ohms-cm.
7. The battery of claim 2, wherein the trap layer comprises at least carbon and a polymer.
8. The battery of claim 7, wherein carbon is a conductive carbon such as carbon nanotubes.
9. The battery of claim 7, wherein the carbon is selected from carbon black, acetylene black, carbon nanotubes, graphene, or combinations thereof.
10. The battery of claim 2, wherein the conductive coating comprise a conductive polymer.
11. The battery of claim 10, wherein the conductive polymer is selected from a poly-acetylene, a poly-thiophene, a poly-aniline, a poly-pyrrole, or combinations thereof.
12. The battery of claim 1, wherein the battery separator is a coated or uncoated battery separator and the battery separator comprises a trap layer in the middle of the battery separator or on a side of the battery separator closest to the anode.
13. The battery of claim 12, wherein the battery separator comprises a trap layer in the middle of the battery separator.
14. The battery of claim 12, wherein the battery separator comprises a trap layer on the side of the battery separator closest to the anode.
15. The battery of claim 12 to 14, wherein the battery separator is formed by a co-extrusion process, a lamination process, or combinations thereof.
16. The battery of claim 15, wherein the battery separator is formed by a coextrusion process or a combination of a coextrusion process and a lamination process.
17. The battery of claim 12, wherein the trap layer has a potential difference vs. Li+/Li that is in the range of +0.0V to +5.0V.
18. The battery of claim 17, wherein the potential difference vs. Li+/Li that is in the range of +0.0V to +3.39V.
19. The battery of claim 17, wherein the potential difference vs. Li+/Li that is in the range of +0.0V to +3.0 V.
20. The battery of claim 12, wherein the trap layer has a bulk or volume resistivity of 10.sup.4 to 10.sup.9 ohms-cm or 10.sup.4 to 10.sup.8 ohms-cm.
21. The battery of claim 20, wherein the trap layer has a bulk or volume resistivity of 10.sup.4 to 10.sup.7 ohms-cm.
22. The battery of claim 12, wherein the trap layer comprises at least carbon and a polymer.
23. The battery of claim 22, wherein carbon is a conductive carbon such as carbon nanotubes.
24. The battery of claim 22, wherein the carbon is selected from carbon black, acetylene black, carbon nanotubes, graphene, or combinations thereof.
25. The battery of claim 12, wherein the trap layer comprise a conductive polymer.
26. The battery of claim 25, wherein the conductive polymer is selected from a poly-acetylene, a poly-thiophene, a poly-aniline, a poly-pyrrole, or combinations thereof.
27. The battery of claim 1, wherein the cathode comprises Lithium Nickel Cobalt Manganese Oxide (NMC or NCM), Lithium Iron Phosphate (LFP), Lithium Nickel Manganese Spinel (LMNO), Lithium Nickel Cobalt Aluminum Oxide (NCA), Lithium Manganese Oxide (LMO), Lithium Cobalt Oxide (LCO), or combinations thereof.
28. The battery of claim 13, wherein the battery separator is formed by a co-extrusion process, a lamination process, or combinations thereof.
29. The battery of claim 14, wherein the battery separator is formed by a co-extrusion process, a lamination process, or combinations thereof.
30. The battery of claim 13, wherein the trap layer has a potential difference vs. Li+/Li that is in the range of +0.0V to +5.0V.
31. The battery of claim 14, wherein the trap layer has a potential difference vs. Li+/Li that is in the range of +0.0V to +5.0V.
32. The battery of claim 13, wherein the trap layer has a bulk or volume resistivity of 10.sup.4 to 10.sup.9 ohms-cm or 10.sup.4 to 10.sup.8 ohms-cm.
33. The battery of claim 14, wherein the trap layer has a bulk or volume resistivity of 10.sup.4 to 10.sup.9 ohms-cm or 10.sup.4 to 10.sup.8 ohms-cm.
34. The battery of claim 13, wherein the trap layer comprises at least carbon and a polymer.
35. The battery of claim 14, wherein the trap layer comprises at least carbon and a polymer.
36. The battery of claim 13, wherein the trap layer comprise a conductive polymer.
37. The battery of claim 14, wherein the trap layer comprise a conductive polymer.
38. A battery separator adapted to be placed between the anode and the cathode of a secondary battery that generates or comprises metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, chrome or Cr ions, molybdenum ions, tin ions or combinations thereof, the battery separator comprising: a coated or uncoated battery separator having a trap layer on at least one side thereof or in the middle thereof, wherein the trap layer is at least one of: a coating on an anode-facing side; has a potential difference vs. Li+/Li that is in the range of +0.0V to +5.0V; has a potential difference that is in the range of +0.0 to +3.39 V; has a potential difference that is in the range of +0.0 to +3.0 V; has a bulk or volume resistivity of 10.sup.4 to 10.sup.9 ohms-cm; has a bulk or volume resistivity of 10.sup.4 to 10.sup.8 ohms-cm; has a bulk or volume resistivity of 10.sup.4 to 10.sup.7 ohms-cm; at least carbon and a polymer; at least carbon and a polymer wherein the carbon is a conductive carbon such as carbon nanotubes; at least carbon and a polymer wherein the carbon is selected from carbon black, acetylene black, carbon nanotubes, graphene, or combinations thereof; a conductive coating comprising a conductive polymer; a conductive coating comprising a conductive polymer wherein the conductive polymer is selected from a poly-acetylene, a poly-thiophene, a poly-aniline, a poly-pyrrole, or combinations thereof; a trap layer in the middle of the battery separator or on a side of the battery separator closest to the anode; a trap layer in the middle of the battery separator; and/or, a trap layer on the side of the battery separator closest to the anode.
39. The battery separator of claim 38, wherein the trap layer is at least two of: a coating on an anode-facing side; has a potential difference vs. Li+/Li that is in the range of +0.0V to +5.0V; has a potential difference that is in the range of +0.0 to +3.39 V; has a potential difference that is in the range of +0.0 to +3.0 V; has a bulk or volume resistivity of 10.sup.4 to 10.sup.9 ohms-cm; has a bulk or volume resistivity of 10.sup.4 to 10.sup.8 ohms-cm; has a bulk or volume resistivity of 10.sup.4 to 10.sup.7 ohms-cm; at least carbon and a polymer; at least carbon and a polymer wherein the carbon is a conductive carbon such as carbon nanotubes; at least carbon and a polymer wherein the carbon is selected from carbon black, acetylene black, carbon nanotubes, graphene, or combinations thereof; a conductive coating comprising a conductive polymer; a conductive coating comprising a conductive polymer wherein the conductive polymer is selected from a poly-acetylene, a poly-thiophene, a poly-aniline, a poly-pyrrole, or combinations thereof; a trap layer in the middle of the battery separator or on a side of the battery separator closest to the anode; a trap layer in the middle of the battery separator; and/or, a trap layer on the side of the battery separator closest to the anode.
40. The battery separator of claim 38, wherein the trap layer is at least three of: a coating on an anode-facing side; has a potential difference vs. Li+/Li that is in the range of +0.0V to +5.0V; has a potential difference that is in the range of +0.0 to +3.39 V; has a potential difference that is in the range of +0.0 to +3.0 V; has a bulk or volume resistivity of 10.sup.4 to 10.sup.9 ohms-cm; has a bulk or volume resistivity of 10.sup.4 to 10.sup.8 ohms-cm; has a bulk or volume resistivity of 10.sup.4 to 10.sup.7 ohms-cm; at least carbon and a polymer; at least carbon and a polymer wherein the carbon is a conductive carbon such as carbon nanotubes; at least carbon and a polymer wherein the carbon is selected from carbon black, acetylene black, carbon nanotubes, graphene, or combinations thereof; a conductive coating comprising a conductive polymer; a conductive coating comprising a conductive polymer wherein the conductive polymer is selected from a poly-acetylene, a poly-thiophene, a poly-aniline, a poly-pyrrole, or combinations thereof; a trap layer in the middle of the battery separator or on a side of the battery separator closest to the anode; a trap layer in the middle of the battery separator; and/or, a trap layer on the side of the battery separator closest to the anode.
41. The battery separator of claim 38, wherein the battery separator is formed by a co-extrusion process, a lamination process, or combinations thereof.
42. The battery separator of claim 38, wherein the battery separator is formed by a coextrusion process or a combination of a coextrusion process and a lamination process.
43. In a secondary battery that generates or comprises metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, chrome or Cr ions, molybdenum ions, tin ions or combinations thereof, the improvement comprising the battery separator of claim 38.
44. In a secondary battery that generates or comprises metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, chrome or Cr ions, molybdenum ions, tin ions or combinations thereof, the improvement comprising the battery separator of claim 39.
45. In a secondary battery that generates or comprises metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, chrome or Cr ions, molybdenum ions, tin ions or combinations thereof, the improvement comprising the battery separator of claim 40.
Description
DESCRIPTION OF THE FIGURES
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DETAILED DESCRIPTION
[0035] Disclosed herein is a secondary battery that has or is susceptible to metal contamination and has improved useful life due at least in part to the separator utilized therein. The battery may comprise, consist of, or consist essentially of, an anode, a cathode, a separator between the anode and the cathode, and an electrolyte. The separator may be a coated separator or an uncoated separator, and a trap layer may be part of the separator, part of the coating, or both part of the separator and part of the coating. Where the trap layer is part of the separator, it is preferably in the middle of the separator or on a side of the separator closest to the anode. When the trap layer is part of a coating (trap layer coating), it is part of a coating on an anode-facing side of the separator. Examples of secondary batteries according to some embodiments described herein are shown in
[0036] Cathode
[0037] The cathode of the secondary battery described herein is not so limited, but may preferably be a cathode-material that generates metal ion contamination in the battery. For example, the cathode material may transition-metal-containing compounds that can be used for the cathode. In some embodiments, the cathode material may be selected from Lithium Nickel Cobalt Manganese Oxide (NMC or NCM), Lithium Iron Phosphate (LFP), Lithium Nickel Manganese Spinel (LMNO), Lithium Nickel Cobalt Aluminum Oxide (NCA), Lithium Manganese Oxide (LMO), Lithium Cobalt Oxide (LCO), or combinations thereof.
[0038] Anode
[0039] The Anode material of the secondary battery described herein is not so limited, and may be any anode-material for use in a secondary battery. In some preferred embodiments, the anode material may be one susceptible to metal-ion contamination in the cell such as graphite.
[0040] Electrolyte
[0041] The electrolyte material of the secondary battery described herein is not so limited, and any electrolyte suitable for use in a secondary battery may be used. In some preferred embodiments, the electrolyte is a liquid electrolyte.
[0042] Separator
[0043] The separator herein may be one of the following: an uncoated separator comprising a trap layer, a coated separator where the coating comprises a trap layer, a coated separator where the separator comprises a trap layer, or a coated separator where the coating and the separator comprise a trap layer
[0044] Uncoated Separator Comprising a Trap Layer
[0045] The uncoated separator Comprising a Trap Layer may be a porous membrane with one or more trap layers therein. The one or more trap layers may be external layers, see
[0046] The uncoated separator with a trap layer may, in preferred embodiments, be a microporous membrane.
[0047] The uncoated separator with a trap layer may be formed by any method, but in preferred embodiments, the uncoated separator with a trap layer may be formed by a dry-stretch method such as the Celgard dry-stretch method. A dry-stretch method may comprise, consist of, or consist essentially of an extrusion (or co-extrusion) step, an annealing step, and a stretching (uniaxially or biaxially) step. A dry-stretch method does not utilize solvents or oils, or uses only minimal amounts. The uncoated separator with a trap layer may also be formed by a wet process that does utilize solvents and/or oils. For example, solvents and/or oils may be used for pore formation in a wet process.
[0048] Coated Separator with Trap Layer
[0049] The coated separator may comprise the following: a separator with a trap layer as described hereinabove (see also
[0050] The separator without a trap layer is not so limited and may be any porous or microporous membrane suitable for use as a battery separator. In some preferred embodiments, the separator without a trap layer may comprise, consist of, or consist essentially of one or more polyolefins, including polypropylene, polyethylene, copolymers thereof, or mixtures thereof. The separator without a trap layer may be a monolayer membrane, a bilayer membrane, a trilayer membrane, or a multilayer membrane. The separator without a trap layer may be formed by any method, but in preferred embodiments, the separator without a trap layer may be formed by a dry-stretch method such as the Celgard dry-stretch method. A dry-stretch method may comprise, consist of, or consist essentially of an extrusion (or co-extrusion) step, an annealing step, and a stretching (uniaxially or biaxially) step. A dry-stretch method does not utilize solvents or oils, or uses only minimal amounts. The separator without a trap layer may also be formed by a wet process that does utilize solvents and/or oils. For example, solvents and/or oils may be used for pore formation in a wet process.
[0051] Trap Layer
[0052] The trap layer, whether part of the separator, part of the coating, or both part of the separator and part of the coating, may have a potential difference vs. Li+/Li that is in the range of +0.0V to +5.0V, +0.0V to +4.5V, from +0.0V to +4.0V, from +0.0V to +3.5V, from +0.0V to +3.0V, from +0.0V to +2.5V, from +0.0V to +2.0V, from +0.0V to +1.5V, or from or from +0.0V to 1.0V. For example, for the trap layer to be able to trap copper ions, the potential difference would have to be +3.38. Li+/Li is at −3.04V relative to H2/2H+, Cu.sup.2+/Cu is at +0.34V, so the trap layer would have to be at a potential difference of at least +3.38 V relative to Li+/Li to trap the copper ions.
[0053] The trap layer, whether part of the separator, part of the coating, or both part of the separator and part of the coating, has a bulk or volume resistivity of 10 to 10.sup.9 ohms-cm, 10 to 10.sup.8 ohms-cm, 10 to 10.sup.7 ohms-cm, 10 to 10.sup.6 ohms-cm, 10 to 10.sup.5 ohms-cm, 10 to 10.sup.4 ohms-cm, 10 to 10.sup.3 ohms-cm, or 10 to 10.sup.2 ohms-cm. In some preferred embodiments, a resistivity from 10.sup.4 to 10.sup.9 ohms-cm, 10.sup.4 to 10.sup.8 ohms-cm, or 10.sup.4 to 10.sup.7 ohms-cm may be preferred. As shown in
[0054] In some preferred embodiments, the trap layer may comprise, consist of, or consist essentially of carbon and a polymer. In some particularly preferred embodiments, the carbon may be a conductive carbon such as carbon nanotubes. In some embodiments, the carbon is selected from carbon black, acetylene black, carbon nanotubes, graphene, or combinations thereof.
[0055] In other preferred embodiments, trap layer may comprise, consist of, or consist essentially of a conductive polymer. The conductive polymer may be selected from a poly-acetylene, a poly-thiophene, a poly-aniline, a poly-pyrrole, or combinations thereof.
EXAMPLES
[0056] Table 1 below shows the reduction potential for certain transition metal ions and gives the minimum potential difference vs. Li+/Li which the trap layer must have to trap each of the listed metal ions. Trapping of the transition metal ions may mean plating of the ions on the trap layer surface.
TABLE-US-00001 TABLE 1 Minimum Potential difference vs. Li+/Li which is at −3.04 Transition Metal Reduction V relative to H2/2H+ for a Potential functional trap layer Cu.sup.2+/Cu (+0.34 V) >+3.38 V Ni.sup.2+/Ni (−0.26 V) >+2.78 V Fe.sup.2+/Fe (−0.45 V) >+2.59 V Co.sup.2+/Co (−0.28 V) >+2.76 V Mn.sup.2+/Mn (−1.19 V) >+1.85 V Cr.sup.2+/Cr (−0.91 V) >+2.13 V Sn.sup.2+/Sn(−0.14), >+2.9 V Mo.sup.3+/Mo (−0.2 V) >+2.84 V
Example 1
[0057] A polypropylene and a trap layer material comprising polypropylene and carbon nanotubes is co-extruded to form a battery separator like that shown in
Example 2
[0058] A trap layer coating is formed on a polypropylene monolayer battery separator to form a structure like that shown in
Example 3
[0059] Example 3 is like Example 1 except the trap layer material comprises a conductive polymer, not polypropylene and carbon nanotubes.
Example 4
[0060] Example 4 is like Example 2 except the trap layer comprises a conductive polymer, not carbon nanotubes and a polymer binder.
Examples 5 and 6 and Comparative Example 1
[0061] Examples 5 and 6, and Comparative Example 1, were prepared by coating a slurry having a composition as shown in Table 2 onto a surface of a 16 micron polyolefin tri-layer battery separator. The coating in each Example was 4 microns thick.
TABLE-US-00002 TABLE 2 Acrylic Alumina binder thickener CNT Resistivity (%) (%) (%) (%) (Ohm-cm) Example 5 93.95 5 1 0.05 10.sup.5 Example 6 93.99 5 1 0.01 10.sup.10 Comparative 94.00 5 1 0 ND Example 1
[0062] Cells were formed using the separators of Examples 5, 6, and 7. The Cell configuration was as follows. The cell structure was a laminated cell (36 mAh). Electrode size was 50 mm×30 mm. The cathode material was NCM111 and the anode material was graphite. The electrolyte was EC/EMC=1/2, 1M LiPF6, VC1 wt %. A 50 um copper particle was placed on cathode electrode to simulate contamination metal. A schematic drawing of this cell is in
[0063] Charging and discharging conditions are as follows. Charge conditions are 4.2V CCCV 1 mA 0.2 mA cut off. Aging was 3 days (checked voltage drop by internal short circuit). Temperature was 25° C.
[0064] Results are shown in