UNIQUE ELECTRODES FOR ELECTROCHEMICAL CELLS
20220320539 · 2022-10-06
Assignee
Inventors
Cpc classification
H01G11/28
ELECTRICITY
H01M4/133
ELECTRICITY
H01M8/04283
ELECTRICITY
H01G11/02
ELECTRICITY
Y02E60/13
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
H01G11/24
ELECTRICITY
H01G11/36
ELECTRICITY
International classification
H01M8/04276
ELECTRICITY
H01G11/02
ELECTRICITY
H01G11/24
ELECTRICITY
H01G11/36
ELECTRICITY
H01M4/133
ELECTRICITY
Abstract
An electrode for electrochemical cells including an electrically conductive cohesive membrane having a thickness defined by a first surface and a second surface opposite the first surface; ohmic impedance independent of membrane thickness; simultaneous uniform charge/discharge throughout membrane thickness; the membrane comprising open cell pores and surfaces; a current collector electrically strongly coupled to the entire membrane thickness; and pins extending through the membrane from the first surface to the second surface; the pins electrically coupled to the current collector having eliminated prior art problematical interfacial layers.
Claims
1. An electrode for electrochemical cells comprising: an electrically conductive cohesive membrane having a thickness defined by a first surface and a second surface opposite said first surface; said membrane comprising open cell pores and pore surfaces; a current collector electrically coupled to said pore surfaces; and pins extending through said membrane from said first surface to said second surface; said pins electrically coupled to said current collector.
2. The electrode for electrochemical cells according to claim 1, wherein said membrane comprises one of a nanoscale contiguous open cell pore structure and a mesoscopic contiguous open cell pore structure.
3. The electrode for electrochemical cells according to claim 2, wherein said pins saturate said membrane open cell pores in the absence of tearing, piercing nor displacing said first surface and said second surface and said pore surfaces.
4. The electrode for electrochemical cells according to claim 1, wherein each of said pins extend substantially orthogonal from said current collector.
5. The electrode for electrochemical cells according to claim 1, wherein said first surface is substantially parallel to said current collector and said second surface is substantially parallel to said current collector.
6. The electrode for electrochemical cells according to claim 1, further comprising: a gap formed between said first surface and said current collector, wherein said first surface is adjacent to said current collector.
7. The electrode for electrochemical cells according to claim 1, wherein a bare metal surface of at least one of; the current collector and pins otherwise exposed to electrolyte is coated with a polymer dielectric.
8. An electrochemical unit cell comprising: a positive electrode and a negative electrode separated by a separator; each of said positive electrode and said negative electrode including a galvanic membrane comprising an electrically conducting contiguous open cell porous membrane structure saturated by electrolyte and faradaic or catalyst materials; said galvanic membrane having a thickness defined by a first surface and a second surface opposite said first surface; a current collector proximate to said first surface; and pins extending through said membrane from said first surface to said second surface; said pins electrically coupled to said current collector.
9. The electrochemical unit cell according to claim 8, wherein said separator is selected from the group consisting of an electrolyte/ion permeable dielectric, polymer electrolyte membrane and solid electrolyte.
10. The electrochemical unit cell according to claim 9, wherein said pins saturate the open cell porous membrane structure.
11. The electrochemical unit cell according to claim 9, wherein the pins include a pin base proximate the current collector and a pin top located opposite the pin base proximate the separator.
12. The electrochemical unit cell according to claim 8, wherein said current collector electrically couples the pins.
13. The electrochemical unit cell according to claim 8, wherein said galvanic membrane within the pin is saturated only with pin material.
14. A process for forming an electrode for an electrochemical unit cell comprising: providing an electrically conductive cohesive galvanic membrane having a thickness defined by a first surface and a second surface opposite said first surface; said galvanic membrane comprising open cell pores and pore surfaces; electrically coupling a current collector to said pore surfaces; and forming pins extending through said galvanic membrane from said first surface to said second surface; and electrically coupling said pins to said current collector.
15. The process of claim 14, wherein said galvanic membrane comprises one of a nanoscale contiguous open cell pore structure and a mesoscopic contiguous open cell pore structure.
16. The process of claim 14, wherein said pins saturate said galvanic membrane open cell pores in the absence of tearing, piercing nor displacing said first surface and said second surface and said pore surfaces.
17. The process of claim 14, wherein said galvanic membrane within the pin is saturated only with pin material.
18. The process of claim 14, further comprising: electrically coupling the pins with the current collector.
19. The process of claim 14, further comprising: forming a gap between said first surface and said current collector.
20. The process of claim 14, wherein said galvanic membrane includes a contiguous open cell pore structure that passes unaltered through the pin with which the galvanic membrane makes unimpeded metallic contact while the galvanic membrane provides rigidity and strength to the pin.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0061] Referring to
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[0065] At
[0066] At
[0067] The disclosure achieves unprecedented low resistance to electrical current by means of novel architecture while simultaneously enabling unrestricted interaction between valence potential chemistry and electrolyte.
[0068] This invention accomplishes an actual metallic bond with zero ohmic resistance in the interface between CC metal and the galvanic membrane.
[0069] The disclosed invention replaces conductive powders that must be applied to non-cohesive structures with free standing cohesive non-woven Carbon Nanotubes, CNT (buckypaper), Carbon Nanofoam, CNF or graphene, GC layers as a porous contiguous open cell current carrying medium. These and other cohesive free standing electrical conducting membrane forms, further described, are preferred as MEA in this invention because of the high nanoscale surface density they contain. 15 nm diameter CNT at 20% solids volume contains ≈5×10.sup.3 cm.sup.2/m1 coatable surface. 80% MEA volume remains for faradaic/catalytic chemistry and electrolyte. CNF with comparable pore diameter subtracts less volume and is 50% more area efficient to provide ≈3×10.sup.4 cm.sup.2/m1 coatable surface. Hereinafter, MEA shall imply the use of galvanic membranes as just described in this paragraph.
[0070] Anodes and cathodes of virtually all electrochemical cells fundamentally comprise a structural combination of the following components. 1) Concentrated micro or nano scale porous surfaces of electrically conductive material, e.g. graphene forms of single crystal amorphous or structured layers, nano tube CNT, open cell foam CNF or conventional graphitic carbon particles that must communicate with and exchange electrical charge with redox faradaic and/or catalytic materials. Said redox materials simultaneously communicate with 2) dielectric electrolyte (solid or liquid). Fuel cells add the further complication of a third phase, namely gas that must share communication with redox, electrically conducting and dielectric electrolyte materials at the nano scale. 3) Suitable carbon structures can efficiently collect charge from chemical reactions, especially when those are strongly coupled to carbon, e.g., catalysts, in electronic double layer supercapacitors (EDLC) and in most faradaic battery couples except at present for Lithium (LIB) cathodes. Carbon can transfer charge over a short distance with reasonably low ohmic resistance. What it cannot do is move that charge into a metal current collector with low resistance across an electrolyte barrier that obtains in all art prior to this invention. This invention completely eliminates that interfacial layer. Charge transfers to cell terminals with metallic resistance.
[0071] There is wide opinion that Li-metal anodes will provide an order of magnitude improvement in energy storage capacity respecting present technology although degradation of the Li-metal electrode during cycling in volatile electrolytes prevents stability and longevity. Solid electrolyte is somewhat more stable but does not yet offer a similar energy storage advantage. An interfacial understanding is necessary for developing strategies to commercialize high-energy density and high-power density rechargeable Li metal anodes. Prior art attempts to attach the Li metal directly onto the metal surface of the current collector that conveys charge transfer to the cell terminals. Except for the disclosure, that cannot be done absent an intervening electrolyte interfacial layer which is a high ohmic resistance barrier that limits area specific current density due to high i.sup.2R heat loss. It also leads to the creation of Solid-Electrolyte Interphase (SEI), dendrite growth short circuit through the dielectric separator (e.g., Celgard™) all collectively limiting cycle ability and stability of the LIB. The cathode is subject to even greater interfacial resistance barriers in present LIB.
[0072] Pressure, ≈1,000 KPa has been applied to assembled polar electrodes in an effort to squeeze out interfacial layers or patterns cut into them to promote attachment to metal surface current collectors with no serious cycling improvement in any of the factors aforementioned producing even faster degradation as fully explored in prior art. Another strategy, but not widely used, employs graphene structures mentioned previously. Si-coated CNT intercalates nearly as much Li as the bare metal on a volumetric basis but attaching the composite membrane to metal surfaces across the interfacial electrolyte layer remains along with all the instabilities hereinabove described. The cathode suffers additional interfacial barriers at its attempt to connect faradaic particles to graphene current collectors that, in turn, cannot attach to the metal current collector without similar barriers. As a result these have not found much use in commerce.
[0073] As further detailed within, these barriers are not merely mitigated they are eliminated. The concept is easier to introduce in terms of EDLC energy storage using CNT as the structural backbone or primary current collector. It is more accurately referred to as (Electronic Double Layer Pseudo-capacitance) EDLP best explained by Conway, “Electrochemical Supercapacitors”, pp. 222-223, Plenum (1999). Many examples of polar binary faradaics develop >2.5 volts when fully charged. Ordinary EDLC stores charges at up to ≈0.2 electrons/atom of accessible surface. At 500 to 2,000 μF/cm.sup.2 EDLP on an equivalent charge basis, respectively stores 2.5 to 10 electrons/atom. This is competitive with batteries that store 1 to 3 electrons/atom of bulk phase. The ratio of surface to volume for CNT is 4/Diameter. 15 nm CNT with 80% packing to hold electrolyte contains ≈2×10.sup.6 cm.sup.2/ml and stores 4×10.sup.3 Farad/ml. Energy is ½ CV.sup.2=25×10.sup.3 W.Math.s or Joules/ml. The most popular 18650 LIB provides ≈ 1/10th that energy density. A very conservative estimate for EDLP would put them about on par.
[0074] In virtually all useful cases EDLP faradaics can be very strongly coupled to functionalized CNT surfaces with negligible interfacial resistance. Liquid electrolyte provides capacitive charge storage at densely populated surfaces of CNT. The disclosure goes to attachment of a CNT membrane to metal having no interfacial layer of electrolyte and no Ohmic resistance at the point of attachment. Ion exchange across Helmholtz layers is virtually instantaneous. EDLP has a different discharge profile that best cuts off at half capacity. Finally, the pattern and distribution of attachments is such that the collective resistance of an extended membrane area of any size is less than 10.sup.−5 Ω-cm.sup.2 with profound influence on its use.
[0075] In spite of popular claims to the contrary, standard 18650 LIB can be charged/discharged at recommended ½-C to at most 1C or heat will rapidly degrade cycling performance as earlier noted. Fast charging remains promised but not actually delivered in previously disclosed techniques. In the current disclosure, R in i.sup.2R is reduced by more than 6 orders of magnitude respecting LIB in present use. It follows that i can be increased from less than 10 mA/cm.sup.2(½C) to 1 A/cm.sup.2-area specific electrode in LIB and >10 A/cm.sup.2 in fuel cells. The same applies to EDLP and fuel cells in the disclosure further addressed. What is most important in EDLP is that equivalent series resistance (ESR) allows repetitive half of full capacity cycling at >kHz rates. This should be understood as follows. Capacitor discharge is in accordance with a t=RC time constant where C is in farads and R is the extremely low ESR in this case. Now t can remain extremely short even when electrodes are loaded with very high values of capacity, C. Briefly, half the storable energy can be repetitively charged/discharged in less than 1 millisecond. Deep UV, Excimer or even X-ray laser can be pumped to 3 orders of magnitude higher power than, e.g. a High Energy Liquid Laser Area Defense System (HELLADS) which presently operates at 150 kW. That is a ‘Death Ray’ but a >150 MW focused beam will melt terrestrial rocks from a stationary Earth orbit in less than 120 milliseconds. It is the same energy but 1,000 times faster than present technology. It is concentrated energy (power) that melts rock.
[0076] As catalysts used in this application are universally eligible for strong coupling to CNT surfaces that is a preferred choice for the membrane carbon backbone. The structural stability of a passivated composite galvanic membrane at temperatures to 300° C. make it particularly suited to redox chemistry in hydrocarbon fuel cells.
[0077] The overarching parameter ensuring electric charge transfer with negligible ohmic impedance measured between faradaic chemistry and cell terminals in accordance with the disclosure and related cases cited hereinabove requires a widely distributed pattern of small area current collection locations wherein each said location is not further from similar nearest locations to assure that no point within a GM is further from a metal conductor than three times the thickness of the GM. That criterion is based upon the fact that typical cohesive GM material has in-plane electrical conductivity of at least 100 S.Math.cm.sup.−1 (i.e., 0.01 Ω.Math.cm). Most CNT and CNF membranes meet such criteria at volumetric material density of 20%. Art prior to the disclosure is limited to very thin membrane thickness 50 μm, ergo less energy storage. The opposite is true here where resistance decreases as thickness increases without limit.
[0078] For example, EDLC pseudocapacitance having ESR too low to measure may employ 80% CNT or CNF solid density packed with polar faradaics at higher energy density than any LIB. Of course, LIB can be improved in the same way. Fuel cells will use lower density (20%) to achieve fuel/electrolyte permeability >20 Darcy. Depending upon specific application the optimum membrane solid material density across most electrochemical cell designs will be between 20% and 80%. Fuel cells in accordance with the disclosure will use a membrane thickness chosen to achieve close to 100% oxidation in anodes and reduction of O.sub.2 in cathodes to serve the purpose of the cell. GM thickness is equivalent to process path length, independent of cell ohmic resistance.
[0079] Pins 32 distributed over CC surface 36 in hexagonal array as illustrated in
[0080] The chief attribute of electrodes in accordance with this invention is capacity for unprecedented high current density. Typical LIB C-rate is 0.01 amp/cm.sup.2. It takes 342 cm.sup.2 of popular spiral or prismatic wound 18650 electrode to achieve the 3.2 amp-hr. rating. 1 amp/cm.sup.2 current density does not begin to challenge the limits of this invention. As examples the same area with 100 times faster charging or a stack of 100 electrodes 3.4 cm.sup.2 diameter in series for a 350-volt battery containing the same energy with charging C-rate in 3 minutes. Present fuel cells operate at 1 volt and amp/cm.sup.2 although F. Bacon achieved 1 amp/cm.sup.2 at 0.8V with pressure and alkali electrolyte. The fundamental limit in every case is i.sup.2R heat even for cells operating at high temperature. With >10.sup.−5 reduction in R, i can be increased more than 100-fold.
[0081] Two aspects of this invention are unprecedented regarding popular doctrine, see Newman, J., “Electrochemical Systems” pp. 518-538 Wiley 3.sup.rd Ed. 2004 wherein electron and proton charge transfer R, are inseparable. And it refers to activity profile zones,
[0082] There has been provided an ultralow ohmic resistance electrode for electrochemical cells. While the ultralow ohmic resistance electrode for electrochemical cells has been described in the context of specific embodiments thereof, other unforeseen alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications, and variations which fall within the broad scope of the appended claims.