PRE-LITHIATED SILICON ANODES WITH PVDF BINDER
20170301910 · 2017-10-19
Inventors
- Jun Wang (Shrewsbury, MA, US)
- Paul Gionet (Billerica, MA, US)
- Hungoo Cho (San Jose, CA, US)
- Leslie J. Pinnell (Framingham, MA, US)
- Robert W. Grant (Bedford, NH, US)
Cpc classification
Y02P70/50
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
H01M4/133
ELECTRICITY
H01M4/0459
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
International classification
H01M4/62
ELECTRICITY
H01M4/36
ELECTRICITY
H01M4/133
ELECTRICITY
Abstract
A pre-lithiated silicon anode comprising a PVDF binder at 5-12 wt. % for use in a Li-ion cell is provided. In particular instances, a conductive additive may be added at less than 5 wt. %. The Si anode with PVDF binder is pre-lithiated prior to cell assembly and following Si anode fabrication. The combination of pre-lithiation and PVDF in the Si anode for use in a rechargeable Li-ion cell shows the unexpected result of extending the cycle life.
Claims
1. A Li-ion battery comprising: a cathode comprising a cathode current collector and an electroactive cathode material disposed on one or both sides of the cathode current collector; a pre-lithiated anode; a separator material between the cathode and the anode; an electrolyte in contact with the cathode, the anode, and the separator; the pre-lithiated anode comprising an anode current collector and a silicon electroactive anode material disposed on one or both sides of the anode current collector, wherein the silicon electroactive anode material includes a silicon nanostructure and a PVDF binder present at a weight percent greater than or equal to 5 wt. % of the silicon electroactive anode material.
2. The Li-ion battery of claim 1, wherein the silicon electroactive anode material further includes a carbon based conductive additive.
3. The Li-ion battery of claim 2, wherein the carbon based conductive additive is vapor grown carbon fibers, expanded graphite, carbon black, or combinations thereof.
4. The Li-ion battery of claim 2, wherein the conductive additive is present at less than 5 wt. %.
5. The Li-ion battery of claim 2, wherein the conductive additive is present at less than or equal to 1 wt. %.
6. The Li-ion battery of claim 1, wherein the silicon nanostructure further includes a surface coating.
7. The Li-ion battery of claim 6, wherein the surface coating is less than or equal to 5 wt. %.
8. The Li-ion battery of claim 6, wherein the surface coating is petroleum pitch powder.
9. The Li-ion battery of claim 8, wherein the petroleum pitch powder is carbonized.
10. The Li-ion battery of claim 1, wherein the electrolyte comprises a Li salt and at least one organic solvent.
11. The Li-ion battery of claim 1, wherein the anode current collector is copper.
12. The Li-ion battery of claim 1, wherein the PVDF binder is present at a weight percent less than 12 wt. %.
13. The Li-ion battery of claim 1, wherein the PVDF binder is present at 10 wt. %.
14. The Li-ion battery of claim 1, wherein the silicon nanostructure is a powder composite of silicon and graphite.
15. The Li-ion battery of claim 14, wherein the powder composite is silicon particles with a carbon base.
16. The Li-ion battery of claim 15, wherein the carbon base is graphite.
17. The Li-ion battery of claim 14, wherein the powder composite is present as nanowires grown on a graphite base.
18. A method of preparing a pre-lithiated anode for use in a Li-ion cell comprising: receiving the negative electrode active material wherein the negative electrode active materials is a powder composite of silicon and graphite and the silicon is present as nanostructures; combining the negative electrode active material with a conductive additive at less than 5 wt. % and a PVDF binder present in a range of 5 to 12 wt. % to produce a mixture; coating the mixture on a copper current collector to form a laminate; compressing the laminate to yield an anode; and pre-lithiating the anode.
19. The method of claim 18, wherein the PVDF binder is present at 10 wt. %.
20. The method of claim 18, wherein the silicon nanostructures are silicon nanowires grown on a graphite base.
21. The method of claim 18, wherein the conductive additive is vapor grown carbon fibers, expanded graphite, carbon black or combinations thereof.
22. The method of claim 18, wherein the conductive additive is present at less than or equal to 1 wt. %.
23. The method of claim 18, wherein the silicon nanostructures further includes a surface coating.
24. The method of claim 23, wherein the surface coating is less than or equal to 5 wt. %.
25. The method of claim 23, wherein the surface coating is petroleum pitch powder.
26. The method of claim 25, where in the petroleum pitch powder is carbonized.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018]
DETAILED DESCRIPTION
[0019] Aspects of this disclosure will now be described by example and with reference to the illustrated embodiments listed above. Components, process steps, and other elements that may be substantially the same in one or more embodiments are identified coordinately and are described with minimal repetition. It will be noted, however, that elements identified coordinately may also differ to some degree.
[0020] The present application relates to a Li-ion rechargeable battery which comprises a Si anode capable of intercalating and releasing lithium, a positive electrode, a separator, and a nonaqueous electrolytic solution consisting of a lithium salt and at least one organic solvent. The Si anode may be fabricated, as described in
[0021] Illustrated in
[0022] In the prior art, to determine the effectiveness of a specific binder, care is taken to test cycles with cycle numbers of 20 to 100. However, the inventors recognized that additional cycles beyond 100 leads to unexpected results of the disclosed specific anode fabrication.
[0023] Turning to
[0024] At step 202, the Si electroactive material may be obtained. In one example, a Si nanostructure electroactive material may be obtained. In another example, a silicon oxide may be obtained. In yet another example, the silicon electroactive material may be a nanoparticle or a nanowire. In the example provided, the Si nanowire electroactive material may be present as a Si graphite composite powder from Si nanowires grown on a graphite base. In other examples, the Si may be present as Si, an alloy or intermetallic compound of Si, or an oxide, carbide, nitride, sulfide, phosphide, selenide, telluride, antimonide, or their mixtures of Si, for example. The Si may be present as a silicon nanostructure. In one example, the Si may be present as Si nanowires. In another example, the Si may be present as Si nanoparticles. The Si electroactive material may be used as a starting material in a non-lithiated form due to the unique processing method provided in the current application. Further, a surface coating, such as a conductive coating, may be applied to protect the silicon and enhance the conductivity. Surface coatings may be commonly included in silicon anode electrochemically active materials. The surface coatings may enable high energy density in Li-ion batteries. In one example, petroleum pitch powder may be added. The surface coating may be present in a percentage range of less than 5 wt. %.
[0025] At step 204, a slurry mixture may be created. A slurry is created by mixing the Si electroactive material together with the conductive additive and the binder as well as a non-aqueous liquid. The conductive additive may be different and used in addition to the surface coating applied at step 202.
[0026] At step 206, a conductive additive, which is different from the surface coating applied to the electroactive material described in step 202, may be mechanically mixed with the Si nanowire electroactive material. The conductive additive may facilitate better conduction and distribution of Li ions during pre-lithiation. In one example, the conductive additive may be vapor grown carbon fibers. In another example, the conductive additive may be expanded graphite or carbon black. In yet another example, the conductive additive may be graphene particles. The conductive additive may be present at equal to or less than 5 wt. %. In one example, the conductive additive may be present at 1 wt. %. In another example, no conductive additive may be present. In one example, the conductive additive may be mixed with the anode electroactive material.
[0027] At step 208, a binder may be mixed with the Si nanowire electroactive material. In one example, the binder may be present as PVDF. The binder may be present at a weight percent between 5 wt. % and 12 wt. %. In one example, the PVDF binder is present at 10 wt. %.
[0028] At 210, the slurry made by mixing the Si nanowire electroactive material with a conductive additive and a PVDF binder is coated on a copper (Cu) current collector. The slurry is dried on the current collector and compressed to fabricate the silicon anode at step 212. In one example, the slurry may be coated on both sides of the Cu current collector. In another example, the slurry may be coated on one side of the Cu current collector.
[0029] At step 214, the fabricated silicon anode may be pre-lithiated. Pre-lithiation of the Si anode inserts Li ions into the anode active material prior to assembly into a Li-ion cell. In one example, the Si anode may be pre-lithiated using an electrochemical process including a lithium salt or chalcogenide as described in Grant et al in U.S. Pat. No. 8,529,746, which is hereby incorporated by reference herein in its entirety. Further, during the electrochemical pre-lithiation step, use of solid electrolyte interface (SEI) additives may be incorporated. The SEI additives may not be desirable for use in a Li-ion cell. In another example, a Li metal powder may be mixed with the anode composite material. In yet another example, an electrochemical process including Li foil may be used to pre-lithiate an anode.
[0030] Thus, a Si anode comprising a PVDF binder and conductive additive increases the effectiveness of the pre-lithiation process such that there is increased efficacy and capacity retention when the Si anode is assembled into a Li-ion cell.
[0031] At step 216, the pre-lithiated silicon anode may be assembled into the Li-ion cell. The Li-ion cell may comprise a cathode including a cathode current collector, a separator, an electrolyte, and a pre-lithiated silicon anode fabricated as described above. The Li-ion cell may show improved cycle life over 1000 cycles, retaining about 70% capacity.
[0032] One example of fabricating a Si anode following method 200 may include a Si electrochemically active material, a surface coating, a binder in a range of 5-12 wt. %, and a low percent of conductive additive wherein the surface coating and conductive additive are different materials and used for differing purposes. The Si electrochemically active material may be prepared from an anode powder, such as a composite of silicon and graphite wherein the silicon powder comprises silicon nanowires grown on a graphite base. The anode powder may be combined with a binder, wherein the binder may be PVDF. The anode powder and binder mixture may then be coated onto a copper current collector and then calendered to fabricate an anode. The fabricated Si anode may then be pre-lithiated prior to assembly in a Li-ion battery cell as described in method 200.
[0033] Thus, method 200 provides a unique approach to fabricating an enhanced pre-lithiated Si anode. The Si anode is fully fabricated prior to the pre-lithiation treatment allowing for the binder and conductive additive to be incorporated prior to the pre-lithiation step. Further, pre-lithiation is performed prior to the Li-ion cell assembly, allowing for SEI forming additives to be incorporated which may not be desirable for use in the assembled Li-ion cell.
[0034]
[0035] A silicon anode 302 such as described in regards to
[0036] The cathode 306 may include a cathode active material on a cathode current collector. The cathode active material may be one of a NCA, a Li oxide, such as a Lithium metal oxide for example, a material capable of intercalating/de-intercalating Li ion, etc. Further, a binder may be mixed with the cathode active material.
[0037] The separator 308 has no particular restriction on the source material or morphology of the separator for the Li-ion cell of the present application. Additionally, the separator serves to separate the anode and the cathode so as to avoid their physical contact. The preferred separator has high ion permeability, a low electrical resistance, excellent stability against the electrolytic solution and excellent liquid holding properties. Example materials for the separator may be selected from nonwoven fabric or porous film made of polyolefins, such as polyethylene and polypropylene, or ceramic coated materials.
[0038] The electrolyte 314 may comprise Li salt, organic solvents, such as organic carbonates, and additives. The electrolyte is present throughout the Li-ion cell and in physical contact with the anode, cathode, and separator. The molar concentration of the lithium salt may be between 0.5 and 2.0 mol/L. The lithium salt may be selected from the group consisting of LiClO.sub.4, LiPF.sub.6, LiBF.sub.4, LiCF.sub.3SO.sub.3, LiN(CF.sub.3SO.sub.2).sub.2, LiN(CF.sub.3CF.sub.2SO.sub.2).sub.2, LiN(CF.sub.3SO.sub.2)(C.sub.4F.sub.9SO.sub.2), LiBOB, LiTFSi, and LiC(CF.sub.3SO.sub.2).sub.3. Further, the electrolyte may comprise aprotic solvents. For example, the solvent may comprise at least one of ethylene carbonate, propylene carbonate, butylene carbonate, dimethyl carbonate, diethyl carbonate, and ethyl methyl carbonate, γ-valerolactone, methyl acetate, methyl propionate, tetrahydrofuran, 2-methyl tetrahydrofuran, tetrahydropyran, dimethoxyethane, dimethoxymethane, ethylene methyl phosphate, ethyl ethylene phosphate, trimethyl phosphate, triethyl phosphate, halides thereof, vinyl ethylene carbonate and fluoroethylenecarbonate, poly(ethylene glycol), diacrylate, and combinations thereof
[0039] Thus, a Li-ion cell may be fabricated comprising the pre-lithiated silicon anode, the cathode, the separator and the electrolyte. The Li-ion cell as described may be fabricated as a prismatic cell in one example. The Li-ion cell may be used in rechargeable batteries to provide the unexpected result of improved cycle life performance due to the particular ordering of the method steps, including fabricating the silicon anode prior to any pre-lithiation treatment.
[0040] Turning to
[0041] Turning to
[0042] The combination of the flexibility and inherent resilience of the PVDF binder, which allows for expansion and contraction of Si, and the pre-lithiation process, which provides Li ions to the anode before use in a Li-ion cell, provides the unexpected properties seen in the pre-lithiated Si/PVDF anode used in high energy density rechargeable cells. Thus, the PVDF binder combined with the Si/C anode active material prior to pre-lithiation provides an anode with a flexible binder which may allow for initial pulverization as the anode expands and contracts during initial cycling of the cell resulting in an initial capacity decrease. However, the flexibility of the binder, allows for the capacity retention to level off over about 1000 cycles, thereby extending the cycle life of the electrochemical cell. This approach relies on the fabrication of the electrode with the binder prior to the pre-lithiation step and provides the unexpected result of extended cycle life.
[0043]
[0044]
[0045] Turning to
[0046] In this way, Li-ion cells were made using pre-lithiated Si/C anodes wherein the anode comprises a silicon graphite composite, PVDF binder, and a carbon conductive additive. The pre-lithiated Si/C anodes comprising PVDF and a carbon powder may stabilize capacity loss after 100 cycles and show the unexpected result of improving cycle life over 1000 cycles at a C/2 charge/discharge rate, providing about 70% capacity retention. This Si anode combination along with pre-lithiation following anode fabrication provides an unexpected result of extended cycle life given the extensive research and recommendation for the use of water based binders to mitigate the effects of silicon expansion.
[0047] Those skilled in the art will also understand that there can be many variations made to the operations of the techniques explained above while still achieving the same objectives of the invention. Such variations are intended to be covered by the scope of this invention. As such, the foregoing description of embodiments of the invention are not intended to be limiting. Rather, any limitations to embodiments of the invention are presented in the following claims.
[0048] Various modifications of the present disclosure, in addition to those shown and described herein, will be apparent to those skilled in the art of the above description. Such modifications are also intended to fall within the scope of the appended claims.
[0049] It is appreciated that all reagents are obtainable by sources known in the art unless otherwise specified.
[0050] Patents, publications, and applications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These patents, publications, and applications are incorporated herein by reference to the same extent as if each individual patent, publication, or application was specifically and individually incorporated herein by reference.
[0051] The foregoing description is illustrative of particular embodiments of the invention, but is not meant to be a limitation upon the practice thereof.
[0052] The foregoing discussion should be understood as illustrative and should not be considered limiting in any sense. While the inventions have been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the inventions as defined by the claims.
[0053] The corresponding structures, materials, acts and equivalents of all means or steps plus function elements in the claims below are intended to include any structure, material or acts for performing the functions in combination with other claimed elements as specifically claimed.
[0054] Finally, it will be understood that the articles, systems, and methods described hereinabove are embodiments of this disclosure—non-limiting examples for which numerous variations and extensions are contemplated as well. Accordingly, this disclosure includes all novel and non-obvious combinations and sub-combinations of the articles, systems, and methods disclosed herein, as well as any and all equivalents thereof.