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WO2025184060A1 - Joint d'isolation et batteries à électrolyte solide le comprenant - Google Patents

Joint d'isolation et batteries à électrolyte solide le comprenant

Info

Publication number
WO2025184060A1
WO2025184060A1 PCT/US2025/017133 US2025017133W WO2025184060A1 WO 2025184060 A1 WO2025184060 A1 WO 2025184060A1 US 2025017133 W US2025017133 W US 2025017133W WO 2025184060 A1 WO2025184060 A1 WO 2025184060A1
Authority
WO
WIPO (PCT)
Prior art keywords
electrode
insulation gasket
current collector
layer
electrode tab
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2025/017133
Other languages
English (en)
Inventor
Kwan Li
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Factorial Inc
Original Assignee
Factorial Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Factorial Inc filed Critical Factorial Inc
Publication of WO2025184060A1 publication Critical patent/WO2025184060A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/183—Sealing members
    • H01M50/186—Sealing members characterised by the disposition of the sealing members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/183—Sealing members
    • H01M50/184—Sealing members characterised by their shape or structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/183—Sealing members
    • H01M50/19—Sealing members characterised by the material
    • H01M50/193—Organic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/533—Electrode connections inside a battery casing characterised by the shape of the leads or tabs
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/572—Means for preventing undesired use or discharge
    • H01M50/584—Means for preventing undesired use or discharge for preventing incorrect connections inside or outside the batteries
    • H01M50/586—Means for preventing undesired use or discharge for preventing incorrect connections inside or outside the batteries inside the batteries, e.g. incorrect connections of electrodes
    • Y—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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • This disclosure relates to an insulation gasket and electrochemical devices with the same.
  • a solid electrolyte instead of liquid electrolyte is employed to improve flammability, safety and other properties of solid-state batteries.
  • a layer of a solid electrolyte is sandwiched between a cathode layer and an anode layer, wherein the cathode layer comprises a cathode tab extending from a cathode current collector and an anode tab extending from an anode current collector.
  • an electrochemical device such as solid-state battery comprises multiples cathode tabs and anode tabs.
  • a press during manufacturing such as warm isostatic pressing (WIP) is usually required to minimize the interfacial electrode/electrolyte resistance.
  • WIP warm isostatic pressing
  • one of the electrode tabs may accidentally touch the other electrode due to the displacement during manufacturing, leading to short circuiting.
  • the press may break or detach the electrode tabs due to the shear force around the edges of the solid electrolyte layer and/or electrode layer.
  • a cell assembly that includes an insulation gasket comprising a foldable extension and surrounding a layer of a first electrode comprising a first current collector with a first electrode tab, wherein the foldable extension, upon folding, turns into a folded extension covering a layer of second electrode, thus electrically insulating the first electrode tab from the layer of the second electrode.
  • An electrochemical device comprising the insulation gasket is also disclosed.
  • an electrochemical device further comprises a second insulation gasket surrounding the periphery of a layer of the second electrode and comprising a second foldable extension, wherein, the second insulation gasket, upon folding, turns into a second folded extension covering a layer of the first electrode.
  • FIG. 1 illustrates a view of a cell assembly according to one embodiment of the present disclosure.
  • Fig. 2A shows a cross-section view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 2B shows a cross-section view of an insulation gasket according to another embodiment of the present disclosure.
  • Fig. 2C shows a cross-section view of an insulation gasket according to one embodiment of the present disclosure.
  • Figs. 3A and 3B show a cell assembly within an insulation gasket prior to and after folding, respectively, according to some embodiments of the present disclosure.
  • Fig. 6A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 6B shows a cross-section view along B-B’ in Fig. 6A according to one embodiment of the present disclosure.
  • Fig. 7A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 7B shows a cross-section view along C-C’ in Fig. 7A according to one embodiment of the present disclosure.
  • Fig. 8A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 8B shows a cross-section view along Cl -Cl’ in Fig. 8A according to one embodiment of the present disclosure.
  • Fig. 9A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 9B shows a cross-section view along C2-C2’ in Fig. 9A according to one embodiment of the present disclosure.
  • Fig. 10A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 10B shows a cross-section view along C3-C3’ in Fig. 10A according to one embodiment of the present disclosure.
  • Fig. 11A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 11B shows a cross-section view along D-D’ in Fig. 11 A according to one embodiment of the present disclosure.
  • Fig. 12A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 12B shows a cross-section view along E-E’ in Fig. 12A according to one embodiment of the present disclosure.
  • Fig. 13A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 13B shows a cross-section view along F-F’ in Fig. 13A according to one embodiment of the present disclosure.
  • Fig. 14A shows a right view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 14B shows a cross-section view along G-G’ in Fig. 14A according to one embodiment of the present disclosure.
  • Figs. 15A-15F show representative connections between the gasket ring and the foldable extension according to some embodiments of the present disclosure.
  • Fig. 16 shows a view of an insulation gasket after folding electrode tabs according to one embodiment of the present disclosure.
  • Fig. 17 shows a view of an insulation gasket according to one embodiment of the present disclosure.
  • Fig. 18 shows a view of an insulation gasket after folding electrode tabs according to one embodiment of the present disclosure.
  • a cell assembly that reduces the potential for short circuiting by separating and insulating cathode tabs from anodes and/or separating and insulating anode tabs from cathodes. This is accomplished by having a cell assembly with an insulation gasket comprising a foldable extension and surrounding the periphery of a layer of a first electrode comprising a first current collector with a first electrode tab, wherein the foldable extension, upon folding, turns into a folded extension covering at least a part of the periphery of a layer of second electrode, thus electrically insulating the first electrode tab from the layer of the second electrode.
  • An electrochemical device comprising the insulation gasket is also disclosed.
  • the cell assembly and electrochemical device further comprises a second insulation gasket surrounding the periphery of a layer of the second electrode and comprising a second foldable extension, wherein, the second insulation gasket, upon folding, turns into a second folded extension covering at least a part of the periphery of a layer of the first electrode.
  • Fig. 1 is a view of a cell assembly without showing insulation gaskets according to one embodiment of the present disclosure.
  • the cell assembly comprises a first electrode layer (10), a solid electrolyte layer (20), and a second electrode layer (30).
  • the first electrode layer (10) comprises a first electroactive material layer (11) on at least one side of a first current collector (12) with a first electrode tab (1201) protruding or extending therefrom.
  • the first electrode is either cathode or anode.
  • the second electrode layer (30) comprises a second electrode tab (3201) protruding or extending from a second current collector (32).
  • the second electrode layer (30) further comprises a second electroactive material layer (not shown in Fig. 1).
  • an insulation gasket surrounding the periphery of the first electroactive material layer (11).
  • an insulation gasket (50) comprises one or more foldable extensions.
  • an insulation gasket (50) comprises a gasket ring (500) and a foldable extension (501) on the right side.
  • an insulation gasket (50) comprises a gasket ring (500) and a foldable extension (501) on the left side.
  • an insulation gasket (50) comprises a gasket ring (500), a first foldable extension (501) on one side and a second foldable extension (502) on the opposing side.
  • the first and second foldable extensions (501 and 502) may be located at the same or different side.
  • the gasket ring (500) has a shape complementary to the periphery of the first electroactive material layer (11), which can be a circular, rectangular or triangular shape or any regular or non-regular shape.
  • the cell assembly may comprise one or more insulation gaskets (50), wherein each insulation gasket (50) surrounds a first electroactive material layer (11).
  • the first electrode tab (1201) is sandwiched between a pair of insulation gaskets, i.e., a first insulation gasket (50_a) underneath the first electrode tab (1201) and a second insulation gasket (50_b) above the first electrode tab (1201).
  • a pair of insulation gaskets i.e., a first insulation gasket (50_a) underneath the first electrode tab (1201) and a second insulation gasket (50_b) above the first electrode tab (1201).
  • their foldable extensions turn into a folded underneath extension (501 l a) and a folded upper extension (501 l b), respectively.
  • the folded underneath extension (501 l a) covers the edge of the solid electrolyte layer (20) and the second electrode layer (30), thus physically separating and electrically insulating the first electrode tab (1201) from the second electrode layer (30). It suppresses and/or avoids short-circuiting therebetween.
  • both the folded underneath extension (501 l a) and the folded upper extension (5011 b) protect the first electrode tab (1201) from any external damage or mechanical failure due to cutting force, compression and/or displacement around the edge, for example when folding the first electrode tab (1201).
  • the first insulation gasket (50_a) and the second insulation gasket (50_b) have the same or different shape.
  • the first insulation gasket (50_a) has a shape complementary to the second insulation gasket (50_b).
  • the cell assembly further comprises a second electroactive material layer on the second current collector and a second set of insulation gasket surrounding the periphery of the second electroactive material layer.
  • the insulation gasket surrounding the first electroactive material layer and placed next to the first electrode tab is referred to as a first set of insulation gaskets.
  • the first set of insulation gaskets may comprise one insulation gasket on either side or each side of the first electrode tab.
  • the insulation gasket surrounding the second electroactive material layer and placed next to the second electrode tab is referred to as a second set of insulation gaskets.
  • the second set of insulation gaskets may comprise one insulation gasket on either side or each side of the second electrode tab.
  • the foldable extension (501) of an insulation gasket (50) has a length (1) and a width (w) as shown in Fig. 4. In some embodiments, the foldable extension (501) has a length (1) smaller than that of the first electrode tab (1201). In some embodiments, the foldable extension (501) has a width equal to or greater than that of the first electrode tab (1201).
  • the foldable extension (501) of the insulation gasket (50) has a height (h) (alternatively thickness) equal to or less than the gasket ring (500). As shown in Fig. 5A and 5B, the foldable extension (501) has a height equal to the gasket ring (500). As shown in Figs. 6A and 6B, the foldable extension (501) has a height (h) from about 40% to 60% of the gasket ring (500).
  • the foldable extension (501) has a length in a range from 1 pm to 3000 pm. In some embodiments, foldable extension (501) has a length in a range from 10 pm to 3000 pm, from 20 pm to 3000 pm, from 50 pm to 3000 pm, from 100 pm to 3000 pm, from 200 pm to 3000 pm, from 300 pm to 3000 pm, or from 500 pm to 3000 pm.
  • foldable extension (501) has a length in a range from 20 pm to 2500 pm, from 50 pm to 2500 pm, from 100 pm to 2500 pm, from 200 pm to 2500 pm, from 300 pm to 2500 pm, from 350 pm to 2500 pm, from 400 pm to 2500 pm, or from 450 pm to 2500 pm. In some embodiments, foldable extension (501) has a length in a range from 25 pm to 2000 pm, from 50 pm to 2000 pm, from 100 pm to 2000 pm, from 200 pm to 2000 pm, from 300 pm to 2000 pm, from 350 pm to 2000 pm, from 400 pm to 2000 pm, or from 500 pm to 2000 pm.
  • foldable extension (501) has a length in a range from 25 pm to 1500 pm, from 50 pm to 1500 pm, from 100 gm to 1500 gm, from 200 gm to 1500 gm, from 300 gm to 1500 gm, from 400 gm to 1500 gm, or from 500 gm to 1500 gm.
  • the foldable extension (501) has a width in a range from 0.1 mm to 50 mm. In some embodiments, foldable extension (501) has a width in a range from 0.1 mm to 40 mm, from 0.5 mm to 40 mm, from 1.0 mm to 40 mm, from 2.0 mm to 40 mm, from 5.0 mm to 40 mm, from 7.5 mm to 40 mm, or from 10 mm to 40 mm.
  • the foldable extension (501) has a width in a range from 0.1 mm to 30 mm, from 0.5 mm to 30 mm, from 1.0 mm to 30 mm, from 4.0 mm to 30 mm, from 5.0 mm to 30 mm, from 7.5 mm to 30 mm, or from 10 mm to 30 mm. In some embodiments, the foldable extension (501) has a width in a range from 0.1 mm to 20 mm, from 0.5 mm to 20 mm, from 1.0 mm to 20 mm, from 4.0 mm to 20 mm, from 5.0 mm to 20 mm, from 7.5 mm to 20 mm, or from 10 mm to 20 mm.
  • the thickness ratio of the foldable extension (501) to the gasket ring (500) is in a range from 25% to 100%, from 25% to 80%, from 25 % to 60%, from 25% to 40%, from 40% to 100%, from 40% to 80%, from 40 % to 60%, or any and all subranges and ranges therebetween.
  • the gasket ring (500) has a thickness equal to or greater than the first electroactive material layer (11).
  • the thickness ratio of the gasket ring (500) to the first electroactive layer (11) is in a range from 100 % to 110%, from 100 % to 120%, from 100 % to 130%, from 100 % to 150%, from 105 % to 110%, from 105 % to 120%, from 105 % to 130%, from 105 % to 150%, from 110 % to 120%, from 110 % to 130%, from 110 % to 150%, from 120 % to 130%, from 120 % to 150%, or any and all subranges and ranges therebetween.
  • the first electroactive material layer (11) has a thickness in a range from 1 gm to 1000 gm, from 1 gm to 850 gm, from 1 gm to 500 gm, from 1 gm to 300 gm, from 1 gm to 250 gm, from 5 gm to 1000 gm, from 10 gm to 1000 gm, from 50gm to 1000 gm, from 75 pm to 1000 pm, from 100 pm to 1000 pm, from 200 pm to 1000 pm, from 10 pm to 800 pm, from 15 urn to 650 pm, from 20 pm to 500 pm, from 25pm to 300 pm, from 75 pm to 300 pm, from 100 pm to 300 pm, or any and all subranges and ranges therebetween.
  • the foldable extension (501) comprises an engineered surface (504). As typically shown in Figs. 7A, 7B, 8A and 8B, the engineered surface (504) is an arc surface. In some embodiments, the foldable extension (501) has a non-fixed height. In some embodiments, the height of the foldable extension is expressed as an average height along the total length of the foldable extension (501). In some embodiments, the foldable extension (501) has a minimum height (hmm) at the end as shown in Fig. 7B. In some embodiments, the minimum height is zero.
  • the engineered surface (504) can be an arc surface such as those in Figs. 7B and 8B. In some embodiments, the engineered surface (504) can be a slope or inclined plane, such as Figs. 9A, 9B, 10A, and 10B. In some embodiments, the engineered surface can also be a laddering surface or any combination thereof.
  • the insulation gasket (50) comprises a channel to accommodate the first electrode tab (1201).
  • the insulation gasket (50) comprises a channel (505) which accommodates the first electrode tab (1201).
  • the channel (505) is an indentation along the surface of the extension or an opening at the gasket ring (500) and/or the extension (501)
  • the channel (505) may reduce the shear force around the edge and thus suppress the damage to the first electrode tab (1201) or detach from the first electrode current collector which is not shown in Figs. 11A and 11B.
  • the channel (505) has a width less than that of the foldable extension (501). In some embodiments, the channel (505) has a width equal to or greater than that of the first electrode tab (1201).
  • the insulation gasket (50) comprises an engineered surface (504) (such as an arc surface or slope or inclined plane) and a channel (505) along the surface as shown in Figs.12A and 12B.
  • the engineered surface (504) may comprise two sub-surfaces, i.e., one along the original engineered surface (5041) and the other one having a lowered height (5042) as shown in Figs. 12A and 12B.
  • the engineered surface (504) guides the folding path and behavior of the first electrode tab (1201).
  • the engineered surface (504) and the channel (505) dissipate or reduce the cutting forces along the edge during compression-decompression cycles, thus protecting the first electrode tab (1201) from detaching from the first current collector (12).
  • the channel (505) may extend from the top surface via an engineered surface, and all the way to the side surface of the foldable extension (501) as shown in Figs. 13A and 13B.
  • the insulation gasket (50) comprises an engineered surface (504) and a channel (505).
  • the engineered surface (504) is further divided into a first subsurface (5041) and a second subsurface (5042), wherein the second subsurface (5042) has a lowered height in comparison to the first subsurface (5041).
  • the arc surface as shown in Figs. 14A and 14B may guide the folding of the first electrode tab (1201) in a controlled manner and protect it by avoiding stress concentration that may happen at a sharp edge or corner.
  • the foldable extension (501) is connected or coupled with the gasket ring (500) via a notched neck to facilitate the folding or arrangement of the foldable extension (501).
  • Representative notched necks (506) are shown in Figs 15A-15F.
  • the notched neck (506) comprises a designed indentation on one side of the foldable extension (501) as representatively shown in Figs. 15A, 15B, 15E and 15F.
  • the notched neck (506) comprises an indentation on two sides as representatively shown in Figs. 15C and 15D.
  • the notched neck (505) is a rectangular (e.g., Fig.
  • the notched neck (506) is a rectangular (e.g., Fig.l5C), triangular, circular or U- shaped (e.g. Fig. 15D), or V-shaped indentation on two opposite or adjacent sides at a portion of the extension (501) next to the gasket ring (500).
  • the notched neck (506) is a cylinder whose cross-section is smaller than that of the protrusion.
  • the notched neck (506) is a circular indentation on both sides at a portion of the foldable extension (501). In some embodiments, the notched neck (506) is formed during preparation of the insulation gasket (50) such as molding. In some embodiments, the notched neck (506) is formed by cutting or etching the foldable extension (501).
  • an electrochemical device comprises a pair of insulation gaskets, i.e., a first insulation gasket (50_a) underneath the first electrode tab (1201) and a second insulation gasket (50_b) above the first electrode tab (1201).
  • a first insulation gasket (50_a) underneath the first electrode tab (1201)
  • a second insulation gasket (50_b) above the first electrode tab (1201).
  • the first insulation gasket (50_a) comprises a second folded extension (502 l a) while the second insulation gasket (50_b) also comprises a second folded extension (5021_b).
  • a first current collector (12) may or may not have an extra edge area not covered by the first electroactive material layer (11). As shown in Figs. 3A, 3B and 15, the first current collector (12) exhibits a surface area higher than that of the first electroactive material layer (11) and comprises an extra edge area not covered by the first electroactive material layer (11) on the left side of the drawings. [0046] In some embodiments and as shown in Fig. 17, the left side of the first electrode current collector (12) has a length substantially the same as the first electroactive material (11), i.e., there is no extra edge area. In some embodiments and as shown in Fig. 18, particularly two dotted cycles, it can be seen that a simple stack of two adjacent insulation gaskets would insulate the left side of the first electrode layer (10) from the second electrode tab (3201) without forming any folded extension.
  • the insulation gasket (50) after folding, has a first folded extension (5011) on one side of the first electroactive layer while the other side does not have any folded extension.
  • the absence of the folded extension on the other side is either because the insulation gasket does not have a second foldable extension or because the insulation gasket does include a second foldable extension, which, however, does not turn into a folded extension due to the supporting effect from the adjacent insulation gasket.
  • the solid electrolyte layer comprises at least one selected from the group consisting of P2S5, Li 2 S — P2S5 — LiX (where X is a halogen element), Li 2 S — P2S5 — Li2O, Li 2 S— P2S5— Li 2 O— Lil, Li 2 S— SiS 2 , Li 2 S— SiS 2 — Lil, Li 2 S— SiS 2 — LiBr, Li 2 S— SiS 2 — LiCl, Li 2 S— SiS 2 — B 2 S 3 — Lil, Li 2 S— SiS 2 — P 2 S 5 — Lil, Li 2 S— B 2 S 3 , Li 2 S— P2S5— Z m Sn (where m and n are each a positive number, and Z is one selected from Ge, Zn and Ga), Li 2 S — GeS 2 , Li 2 S — Si S 2 — Li 3 PO4, Li 2 S — SiS 2 —
  • the first electrode layer comprises a first electroactive material layer on at least one side of a first current collector.
  • the first electroactive material layer is a cathode active material layer.
  • the cathode active material layer comprises at least one selected from the group consisting of LiFePCh, Li x M0 2 , Li x Nii- y -zCoyMlzO 2 and Li x Nii-y-zMn y M2zO2, wherein M is at least one selected from the group consisting of Ni, Co, Mn, Al, B, Fe, Mg, Ca, Sr, Sc, Y, Ti, Zr, V, Nb, Ta, Cr, Mo, W, Rh, Pd, Cu, Zn, Cd, Ga, In, Sn, and rare earth elements, wherein Ml is at least one selected from the group consisting of Mn, Al, B, Fe, Mg, Ca, Sr, Sc, Y, Ti, Zr,
  • the first current collector comprises at least one selected from the group consisting of Al, stainless steel, Cu, Ni, Ti, carbonaceous materials, Ta, Mo, Nb, Sn, Zn, Ag, Au, Cu-Ni alloy, Cu-Zn alloy, Ni-Cr alloy, phosphor bronze and an alloy thereof.
  • the first current collector has a structure selected from the group consisting of foil, mesh and foam.
  • the first current collector and the second current collector are made of the same or different materials.
  • the second electrode layer comprises a second current collector.
  • the second current collector comprises at least one selected from the group consisting of Cu, stainless steel, Ti, Ni, Ta, Mo, Nb, Sn, Zn, Ag, Au, and alloy thereof.
  • the collector foil is made of a material selected from Cu-Ni alloy, Cu-Zn alloy, Ni- Cr alloy and phosphor bronze.
  • the second electrode layer comprises a second current collector without a second electroactive material layer before the first charge/discharge cycle.
  • a second electrode layer that initially comprises a second current collector without a second electroactive material layer may comprise a second electroactive material layer on at least one side of the second current collector.
  • a second electrode layer comprises a second electroactive material layer on at least one side of the second current collector prior to the first charge/discharge cycle.
  • the second electroactive material comprises lithium metal or lithium alloy.
  • a lithium alloy is an alloy of lithium metal with at least one element selected from the group consisting of C, Si, Sn, Ge, B, Al, In, Bi, Sb, Na, Mg, Zn, Au, and Ag.
  • the cell assemblies disclosed herein may be incorporated into an electrochemical device, for example an all-solid-state battery.
  • the present disclosure provides a method for preparing a cell assembly.
  • the method may include: a) positioning a first electrode layer with a first electrode tab extended therefrom, the first electrode layer comprising a first electroactive material layer on at least one side of a first electrode current collector; b) positioning an insulation gasket comprising a foldable extension so that the insulation gasket surrounds a periphery of the first electroactive material layer, c) stacking a solid electrolyte layer and a second electrode layer having a second electrode tab extended therefrom over the first electrode, wherein the solid electrolyte layer is sandwiched between the first and second electrode layers, d) folding the first electrode tab, which turns the foldable extension of the insulation gasket into a folded extension covering the second electrode layer, leading to a pre-assembly with the folded extension, and, e) placing the pre-assembly with the folded extension into a pouch followed by sealing, thereby obtaining a cell assembly wherein the first electrode tab is electrically
  • the folding of the electrode tabs and the foldable extensions of the insulation gasket may be accomplished using a tool or mold to apply pressure to fold the tabs.
  • isostatic pressure may be used.
  • the pressure may be in a range from 200 MPa to 1,000 MPa, 300 MPa to 1,000 MPa, 400 MPa to 1,000 MPa, 500 MP to 1,000 MPa, or any and all ranges and subranges there between.
  • the pressure may be applied for a sufficient amount or period of time for example in a range from 1 minute to 120 minutes, 5 minutes to 120 minutes, 10 minutes to 120 minutes, 30 minutes to 120 minutes, 45 minutes to 120 minutes, 60 minutes to 120 minutes, or any and all ranges and subranges therebetween.
  • the pressure may also be applied at an elevated temperature, for example in a range from 40°C to 100°C, 50°C to 100°C, 60°C to 100°C, 70°C to 100°C, or any and all ranges and subranges therebetween.
  • the cell assembly may be sealed in a pouch.
  • the pouch may be incorporated into an electrochemical device.
  • the cell assemblies are tested for presence of a short circuit by measuring the open circuit voltage (OCV) across the electrode tabs.
  • OCV open circuit voltage
  • a cell assembly comprises: a) a first electrode layer comprising a first current collector, a first electroactive material layer on the first current collector and a first electrode tab protruding from the first current collector; b) a second electrode layer comprising a second current collector and a second electrode tab protruding from the second current collector; c) a solid electrolyte layer between the first electrode layer and the second electrode layer; and d) an insulation gasket surrounding a periphery of the first electroactive material layer, wherein the insulation gasket comprises a folded extension that covers the second electrode layer, thus electrically insulating the first electrode tab from the second electrode layer.
  • the second electrode layer further comprises a second electroactive material layer on the second current collector.
  • the folded extension has a height equal to or greater than the thickness of the second electrode layer being surrounded.
  • the folded extension has a length shorter than the first electrode tab.
  • the folded extension has a width equal to or greater than the first electrode tab.
  • the insulation gasket is compressible. In some embodiments, the insulation gasket exhibits a compressibility greater than that of the first or second electrode, or both.
  • the insulation gasket comprises at least one insulating polymer selected from the group consisting of polypropylene (PP), polyethylene (PE), polyimide, styrene-butadiene rubber (SBR), sulfonated tetrafluoroethylene based fluoropolymer-copolymer, polytetrafluoroethylene (PTFE), poly vinyl alcohol (PVA), polyvinylidene fluoride (PVDF), a polyvinylidene fluoride copolymer, polyethylene oxide (PEO), epoxy resin, silicone resin, silicone rubber, polyurethane, melamine resin, urea resin, alkyd resin, and copolymer thereof.
  • PP polypropylene
  • PE polyethylene
  • SBR styrene-butadiene rubber
  • PVDF polyvinylidene fluoride
  • PEO polyvinylidene fluoride copolymer
  • epoxy resin silicone resin
  • silicone rubber polyurethane
  • melamine resin polyurethan
  • the insulation gasket is placed on one side of the first electrode tab and a second insulation gasket is placed on the other side of the first electrode tab.
  • the first electrode tab after folding, the first electrode tab comprises a first portion along the direction of first current collector and a bent portion intersecting with the first portion, a folded extension of the second insulation gasket covers at least partially the bent portion of the first electrode tab, so that the first and second insulation gaskets protect the first electrode tab from damage.
  • the insulation gasket comprises multiple folded extensions, which are folded toward the same or different directions.
  • the insulation gasket further comprises a channel for accommodating the first electrode tab, which is electrically connected to a first lead tab located outside the insulation gasket.
  • the cell assembly further comprises a second electroactive material layer on the second current collector and a second set of insulation gasket surrounding the periphery of the second electroactive material layer.
  • the insulation gasket either one or two, surrounding the first electroactive material layer and placed next to the first electrode tab, is referred to as a first set of insulation gaskets.
  • the insulation gasket either one or two, surrounding the second electroactive material layer and placed next to the second electrode tab, is referred to as a second set of insulation gaskets.
  • the second set of insulation gasket is made of a material the same as or different from the insulation gasket.
  • the first electrode layer is a cathode layer or an anode layer.
  • the cathode layer comprises at least one selected from the group consisting of LiFePC , LixMCh, LixNii-y-zCoyMlzCh and Li x Nii- y - z Mn y M2zO2, wherein M is at least one selected from the group consisting of Ni, Co, Mn, Al, B, Fe, Mg, Ca, Sr, Sc, Y, Ti, Zr, V, Nb, Ta, Cr, Mo, W, Rh, Pd, Cu, Zn, Cd, Ga, In, Sn, and rare earth elements, wherein Ml is at least one selected from the group consisting of Mn, Al, B, Fe, Mg, Ca, Sr, Sc, Y, Ti, Zr, V, N, Nb, Ta, Cr, Mo, W, Rh,
  • the first current collector is a cathode current collector
  • the first electrode tab is a cathode tab
  • the first current collector and the first electrode tab independently comprise at least one selected from the group consisting of Al, stainless steel, Cu, Ti, Ni, Ta, Mo, Nb, Sn, Zn, Ag, Au, Cu-Ni alloy, Cu-Zn alloy, Ni-Cr alloy, phosphor bronze and alloys thereof.
  • the second current collector is an anode current collector
  • the second electrode tab is an anode tab
  • the anode current collector and the anode tab independently comprise at least one selected from the group consisting of Cu, stainless steel, Ti, Ni, Ta, Mo, Nb, Sn, Zn, Ag, Au, Cu-Ni alloy, Cu-Zn alloy, Ni-Cr alloy, phosphor bronze and alloys thereof.
  • an all-solid-state battery comprises a cell assembly described herein.
  • a compression is applied to the pouch at a temperature for a period of time.
  • the compression is an isostatic compression.
  • the temperature is in a range from 40 to 100 °C
  • the period of time is in a range from 1 to 120 min
  • the compression is in a range from 200 to 1000 MPa.
  • the step b) is conducted either before or after the step c) or concurrently with step c).

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Sealing Battery Cases Or Jackets (AREA)

Abstract

La présente invention porte sur un joint d'isolation entourant une première couche de matériau électroactif d'une première couche d'électrode qui comprend une extension pliable, la première couche de matériau électroactif étant sur au moins un côté d'un premier collecteur de courant avec une première languette d'électrode. Lors du pliage, l'extension pliable du joint d'isolation tourne dans une extension pliée et recouvre une couche d'une seconde électrode, isolant ainsi électriquement la première languette d'électrode de la seconde couche d'électrode. La première électrode peut être une cathode ou une anode. L'invention divulgue également un dispositif électrochimique comprenant le joint d'isolation. Dans certains modes de réalisation, un dispositif électrochimique comprend en outre un second joint d'isolation entourant la périphérie d'une seconde couche d'électrode et comprenant une seconde extension pliable, le second joint d'isolation, lors du pliage, tournant dans une seconde extension pliée recouvrant une couche de la première électrode.
PCT/US2025/017133 2024-02-28 2025-02-25 Joint d'isolation et batteries à électrolyte solide le comprenant Pending WO2025184060A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202463558698P 2024-02-28 2024-02-28
US63/558,698 2024-02-28

Publications (1)

Publication Number Publication Date
WO2025184060A1 true WO2025184060A1 (fr) 2025-09-04

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WO (1) WO2025184060A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030138693A1 (en) * 1999-08-27 2003-07-24 Toshiba Battery Co., Ltd. Flat non-aqueous electrolyte secondary cell
CN202662704U (zh) * 2012-05-23 2013-01-09 宁德新能源科技有限公司 一种软包装锂离子电池
US20160013457A1 (en) * 2014-07-14 2016-01-14 Samsung Sdi Co., Ltd. Flexible secondary battery
KR20200007561A (ko) * 2018-07-13 2020-01-22 주식회사 엘지화학 절연 가스켓 및 이를 포함하는 이차전지
CN211828981U (zh) * 2020-03-20 2020-10-30 天津力神电池股份有限公司 一种具有限位功能的叠片电池立体上垫片及叠片电池
US20240030483A1 (en) * 2022-07-22 2024-01-25 Factorial Inc. Cell assembly and all solid-state battery comprising the same

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030138693A1 (en) * 1999-08-27 2003-07-24 Toshiba Battery Co., Ltd. Flat non-aqueous electrolyte secondary cell
CN202662704U (zh) * 2012-05-23 2013-01-09 宁德新能源科技有限公司 一种软包装锂离子电池
US20160013457A1 (en) * 2014-07-14 2016-01-14 Samsung Sdi Co., Ltd. Flexible secondary battery
KR20200007561A (ko) * 2018-07-13 2020-01-22 주식회사 엘지화학 절연 가스켓 및 이를 포함하는 이차전지
CN211828981U (zh) * 2020-03-20 2020-10-30 天津力神电池股份有限公司 一种具有限位功能的叠片电池立体上垫片及叠片电池
US20240030483A1 (en) * 2022-07-22 2024-01-25 Factorial Inc. Cell assembly and all solid-state battery comprising the same

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