Solid state electrochemical cell

Abstract: A sold state laminar electrochemical cell (10) has an alkali metal anode layer (12), a solid ionically conducting electrolyte layer (14) and a cathode/current collector layer (16). The electrolyte layer (14) is interposed between the alkali metal anode layer (12) and the cathode/current collector layer (16). The cathode/current collector layer (16) comprises an electrically conductive substrate (18) having a plurality of surface voids (20) and a composite cathode composition (22) comprising an intercalation compound, an electrically conductive filler and an ionically conductive electrolyte. The cathode composition (22) is coated on the surface of the substrate (18) facing the electrolyte layer (14) and is maintained in the voids (20) of the surface.

Description: The invention relates to methods of making a solid state electrochemical cell. Solid state electrochemical devices are the subject of intense investigation and development. They are described extensively in the patent literature. See, for example, U.S. Patents 4,303,748 to Armand; 4,589,197 to North; 4,547,440 to Hooper et al.; and 4,228,226 to Christiansen. These cells are typically constructed of an alkali metal foil anode, typically a lithium foil, an ionically conducting polymeric electrolyte, a finely divided transition metal oxide cathode, and a cathode current collector which is attached to the face of the cathode not contacting the electrolyte. The current collector usually employed is a sheet of metal foil such as aluminum, nickel, or stainless steel. Although the above described cells have presented a viable option to older, more traditional secondary type discharge cells, the rechargeability and impedance of the cells have not achieved optimal performance. Part of the problem lies in the failure of the cathode material to form a good electric contact with the current collector. Failure of the cathode material making a good electrical contact with the current collector leads to an overall increase in cell impedance. This in turn, makes it difficult to recharge the cell. In theory, optimal performance occurs if the cathode material is in intimate contact with the cathode current collector, and wherein the cathode current collector has a high surface area to enable uniform contact between the cathode material and the collector. Attempts have been made in the art to increase both the adherence of the cathode material to the current collector, and to increase the surface area of the current collector. However, no such attempts have been made in the field of solid state alkali metal anode cells. For example, U.S. Patent Nos. 4,751,157 and 4,751,158 to Uchiyama et al. disclose cathode materials for use in lithium electrochemical cells. The cathode material comprises a mixed metal oxide as an active material, along with a conductive diluent and a binder which is pressed into electrodes on a nickel screen and sintered under vacuum. The cathode materials are used in cells which contain a liquid electrolyte, and more particularly, those which contain LiAsF₆ in an aprotic solvent, such as methyl formate. U.S. Patent No. 4,416,915 to Palmer et al. discloses a chalcogenide cathode made by applying a slurry of a mixture containing at least one intercalatable layered transition metal chalcogenide cathode active material, a conductivity enhancing agent and a binding agent in a vehicle to a high porosity current collector substrate, for example, foamed metals and glasses which are 97% to 90% porous with 10 to 1000 pores per square inch and adhering the cathode material to the substrate. The cathode material is utilized in a non-aqueous lithium cell having an electrolyte comprising an electrolyte-solvent mixture. U.S. Patent No. 4,560,632 to Alberto discloses a molded porous cathode collector for use in non-aqueous cells. The collector includes a particulate carbonaceous conductive material bonded with a suitable binder, and having on its surface a coating of a vinyl polymer film to improve its mechanical strength and handling characteristics. The cathode collector is used in association with liquid cathode materials. In the field of solid state lithium cells, U.S. Patent No. 4,735,875 to Anderman et al. discloses a cell wherein a cathode material which takes the form of a microporous sheet containing polyethylene, an electrically conductive and electrochemically active particulate material and a plasticizer is laminated to a current collector such as a screen, grid, expanded metal, woven or non-woven fabric formed from efficient electron conductive materials such as carbon, or metal such as copper, aluminum, nickel, steel, lead or iron. Despite the increased surface area of the cathode collector, the Anderman et al. cell does not optimize the adherence of a cathode material to the collector as the cathode material does not necessarily interpenetrate the pores and the collector substrate. Accordingly, there exists a need in the art for a solid state alkali metal cell wherein a highly uniform electrical contact between the cathode material and cathode current collector is Maintained during operation and recharging of the cell. As will become clear from the detailed description herein below of preferred embodiments, the present invention enables the provision of solid state alkali metal anode cells having significant improvements in cell impedance and, in turn, rechargeability. Our cells maintain a tightly adherent contact between the cathode and cathode current collector of the cell. In accordance with the present invention we provide a method of making a solid state electrochemical cell comprising the steps of providing an alkali metal anode layer, a solid ionically conducting electrolyte layer, and a cathode/current collector layer, with said electrolyte layer interposed between said alkali metal anode layer and said cathode/current collector layer; said cathode/current collector layer being produced by taking an electrically conductive substrate having a plurality of surface voids as a consequence of its physical form, being a mesh, a woven or non-woven fabric, a foamed substrate or a carbon material of fibre or fibril laminate form of ultrahigh surface area, or being provided with surface voids by etching or electrodeposition applied to a film or foil, and wet coating a composition comprising a compound suitable for an intercalation process, an electrically conductive filler, preferably carbon particles,and a curable ionically conductive electrolyte on to the surface of said substrate which in the finished cell faces said electrolyte layer and curing said composition in situ so as substantially completely to fill said voids and so that the composition is tightly adhered to said substrate in the said voids. In a particular embodiment, the alkali metal anode comprises a lithium foil, a lithium coated metal foil or a lithium alloy. Further, the cathode/current collector layer can take on a number of different configurations. For example, the cathode/current collector layer can comprise a cathode composition coated on to the surface and surface voids of either an electrically conductive screen, grid, foamed or expanded metal, etched foil, electrodeposited film, woven fabric or non-woven fabric. The configuration of the cathode/current collector substrate enables superior results to be produced by practical examples of our cells for a number of different reasons. First, the direct adherence of the cathode material to the current collector substrate provides an intimate contact between the cathode composition and the current collector. This enables a high amount of electrical contact between the materials and as such, the efficiency of electron transfer is increased. In addition, when the cathode composition is contained within the voids of the collector substrate, increased electrical contact occurs between the cathode composition and the collector substrate as a result of the increased surface area available for contact by the cathode composition. This too results in an overall increase in efficiency of electron transfer. Further, the cell achieves significant drop in cell impedance and a resultant improvement in rechargeability. The invention is hereinafter more particularly described by way of example only with reference to the accompanying drawings, in which: Fig. 1 is an exploded view of an embodiment of a cell constructed in accordance with the instant invention; and Fig. 2 is a view taken along line 2-2 of Fig. 1. A solid state cell constructed in accordance with the present invention is shown in Fig. 1 and designated by element 10. Cell 10 includes alkali metal anode layer 12, solid ionically conducting electrolyte layer 14, and cathode/current collector layer 16. The cell is particularly characterised by electrolyte layer 14 being interposed between alkali metal anode layer 12 and cathode/current. collector layer 16. Cathode/current collector layer 16 comprises a substrate 18 which has a plurality of surface voids 20. As shown in Fig. 1, substrate 18 is in the form of a screen or grid. However, other physical forms such as foamed states, etched foils, electroplated films, woven or non-woven fabrics may be utilized as substrate 18. Maintained within voids 20 is cathode composition 22. Referring now to Fig. 2, it is seen that the surface of substrate 18 which faces electrolyte layer 14 is also coated with cathode composition 22. Laminar thin-cell batteries containing alkali metal anodes are known in the art, and those skilled in the art will appreciate that laminar batteries in accordance with the present invention can have many constructions, such as those including a jelly roll (Swiss roll) or fan folded laminate strip design, both of which are illustrated in our European Application EP-A-0357399 a document relevant only under Article 54(3) EPC. Other constructions are also available. The alkali metal anode layer may take the form of a lithium foil, a lithium coated foil such as nickel or copper foil having a layer of lithium deposited on its surface or a lithium alloy. Lithium is a preferred anode material because it is very electropositive and light in weight. However, other alkali metal materials, such as sodium, may be practiced , The electrolyte layer, which is ionically but not electrically conductive, takes the form of a solid material and is laminated to the alkali metal anode layer and the cathode/current collector layer. The preferred electrolytes are solid solutions of an ionizable alkali metal salt or an alkaline earth salt in an ionically conductive polymer. Still more preferred are solid solutions of an alkali metal salt, an ionically conductive polymer and a plasticizer or liquid electrolyte. General examples of useful ionically conductive polymers are described in U.S. Patent 4,303,748 to Armand and European Application 0 145 498 to Cook. These polymers have repeating units containing at least one heteroatom such as an oxygen or nitrogen atom. They can be represented as polymers having the repeating unit wherein R is hydrogen or a group Ra, -CH₂ORa, -CH₂OReRa, -CH₂N(CH₃)₂, in which Ra is an alkyl group containing 1 to 16 carbon atoms and preferably 1 to 4 carbon atoms or a cycloalkyl group containing 5 to 8 carbon atoms, and Re is an ether group of formula -CH₂-CH₂Op- wherein p is a number from 1 to 100, preferably 1 or 2: or having the repeating unit wherein R' is Ra, or ReRa, as defined above; or having the repeating unit wherein Re and Ra are as defined above. Copolymers of the above polymers may also be useful. It has been found particularly desirable to prepare these electrolytes using a radiation curable composition which includes a monomer of the formulae: where n is about 3 to 50 and R is hydrogen or a C1-C3 alkyl group which are terminated by ethylenically unsaturated moieties or glycidyl moieties represented by A. This method is described in our European Patent Application EP-A-0318161, a document relevant only under Article 54(3) EPC. A particularly useful group of compounds is obtained by reacting a polyethylene glycol with acrylic or methacrylic acid. Polyethylene glycol diacrylate is a particularly preferred polymer. To provide additional structural integrity, triacrylate prepolymers may be added. Preferably, the ionically conductive polymeric materials have a molecular weight of about 200 to 800. Still more preferably they are liquids at temperatures less than 30°C. As to the ionizable salt, formula MX, this is not limiting at all, and is the type in which: M+=Li⁺, Na⁺, K⁺, Ca²⁺, Mg²⁺, NH₄+ X-=I-, ClO₄-, BF₄-, AsF₆-, CF₃SO₃-,CF₃CO₃-, B₁₂H 12 2 -, B₁₀C 10 2 -, BZ₄-,Z designating C₆H₅, or an alkyl or an aryl chain. To produce a solid electrolyte material, the solid solution of the ionizable salt and polymer is mixed with the radiation curable composition and the mixture is cured by exposure to actinic radiation, preferably electron beam or ultraviolet radiation. If ultraviolet radiation is used for curing, an ultraviolet photoinitiator may be added to the composition. The cathode/current collector layer includes a cathode material which is coated on the surface and in the voids of a current collector material. Cathode compositions are known in the art. Typically they comprise an intercalation compound, an ionically conductive solid polymer electrolyte containing solution of an alkali metal salt or alkaline earth salt as defined above, and an electrically conductive filler. A typical formulation may contain about 25 to about 70 parts by weight of intercalation compound, about 2 to about 15 parts of an electrically conductive filler, and about 15 to about 75 parts of the ionically conductive solid solution. The following compounds have been taught in the art as suitable for use in an intercalation process: V₆O₁₃, MoO₂, MnO₂, V₂O₅, TiS₂, MoS₃, Cr₃O₆, Li x V₃O₈, V₃O₈, VS₂, NbSe₂, FeOCl, CrOBr, TiNCl, ZrNCl, HfNBr, FeS, Nis, Co0, Cu0 and WO₂. V₆O₁₃ is particularly preferred. For use as an electrically conductive filler, carbon may be used. In addition to providing a matrix for containing the alkali metal salt, the ionically conductive polymer additionally functions as a binder material to enable the cathode composition to adhere to the collector substrate. Because of its adhesive qualities, acrylated polyethylene oxide is the preferred ionically conductive polymer. For use as an additional adhesive, acrylated polyesters may be selected. Useful collector substrates having a plurality of surface voids include either carbon, copper, aluminum, nickel, steel, lead and iron materials, or combinations thereof, in the following configurations: foamed nickel or similar foamed metals foamed glass that has been plated with an inert or noble metal to increase surface conductivity foamed polymers containing a surface or bulk conductivity agent foamed Ti-, Nb-, Zr-, W-, Ta-carbides foamed molybdenum disilicide reduced metal reacted molecular or carbosieves chemically etched metal foils electrodeposited films carbon, graphite or vitreous carbon fiber or fibril laminates of ultrahigh surface area. Foamed metals in the form of a mesh or grid and chemically etched metal foils are preferred substrates. To produce the cathode/current collector material, the materials used to form the cathode composition are mixed together and coated onto the surface of the current collector substrate facing the electrolyte layer. The solid solution is in a radiation curable composition, so that the cathode composition/collector substrate may be exposed to actinic radiation to cure the radiation curable composition to the collector substrate. The cathode composition substantially completely fills the surface voids of the collector substrate. This provides a greater amount of electrical contact area between the electrically conductive material of the cathode composition and the current collector substrate. This increased contact enables an overall increased cell efficiency to be achieved as a result of a significant drop in cell impedance. The improved efficiency is particularly noticeable during cell recharging. The completed cell may be manufactured utilizing any of a number of different methods. For example, once each of the anode layer, electrolyte layer and cathode/current collector layer are manufactured, they may be laminated together to form a solid state cell. Lamination typically occurs by the application of heat and pressure. Alternatively, however, the electrochemical device can be assembled "wet" and then cured in situ. For example, a lithium coated foil member can be coated with the radiation polymerizable electrolyte composition and overcoated with the cathode coating composition/current collector substrate. These structures can be cured by exposure to electron beam or another source of actinic radiation. Thus, in one method the current collector substrate may be coated with a radiation polymerizable cathode composition. This structure is overcoated with a layer of the radiation polymerizable electrolyte composition described above and assembled with an anodic member such as a lithium foil member or a lithium coated nickel or aluminum member. This assembly may be cured by exposure to electron beam to provide an electrochemical cell. The cured electrolyte and cathode compositions adhere to one another as well as to the metal members associated with the anode and cathode. The process described above can also be reversed. An anodic metal foil member such as lithium coated metal foil can be coated with the radiation polymerizable electrolyte composition described above. A radiation polymerizable cathode composition is coated over the current collector and is assembled with the anode and electrolyte layers. The assembly is subjected to electron beam radiation to produce an electrochemical cell. In another process, the anodic foil member or the current collector substrate may be coated with the appropriate cathode or electrolyte composition and that composition may be cured (e.g., by exposure to radiation when it is radiation curable). The cured composition may be overcoated with the other of the electrolyte or cathode composition thereafter, and the overcoating may be cured or the remaining anodic foil member or current collector substrate may be laminated and then the overcoating cured. The invention is illustrated in more detail by the following non-limiting examples. Comparative Example 1 A cell was produced by first forming a cathode mixture including 45% by weight V₆O₁₃, 4% carbon and 51% of an electrolyte including 70% propylene carbonate, 3% polyethylene oxide, 6% LIC F SO₃ and 21% of a radiation curable acrylate. This mixture was coated onto a 15 µm thick solid nickel foil current collector to a thickness of about 75 µm. The above defined electrolyte was then coated onto the cathode to a thickness. of about 50 µm. A 100 µm thick lithium foil was then laminated onto the electrolyte and the entire structure was subjected to electron beam radiation to cure the cathode and electrolyte. The initial cell impedance at 1 Hz was measured to be about 110 ohms. Example 2 A cell having the identical cathode, electrolyte and anode of Comparative Example 1 was produced by using a 35 µm thick nickel foil which was etched to provide a roughened surface as the current collector. The measured impedance at 1 Hz was 12 ohms. Example 3 A cell having the identical cathode, electrolyte and anode of Comparative Example 1 was produced by using a porous 200 µm thick nickel felt as the current collector. The measured cell impedance at 1 Hz was 8 ohms. Comparative Example 4 A cell Was prepared identical to the cell of Comparative Example 1 with the exception that the cathode contained 53% V₆O₁₃, 8% carbon and 39% electrolyte. The measured cell impedance at 1 Hz was 15 ohms. Example 5 A cell having the identical cathode, electrolyte and anode of Comparative Example 4 was produced using the current collector of Example 2. The measured impedance at 1 Hz was 5 ohms. Example 6 A cell having the identical cathode, electrolyte and anode of Comparative Example 4 was produced using the current collector of Example 3. The measured impedance was 5 ohms. Comparative Example 7 The cell of Comparative Example 4 was discharged at 200 microamperes/cm² at room temperature to lower the voltage from 3 V to 1.5 V. The discharge time was 15 hours. Example 8 The experiment of Comparative Example 7 was repeated using the cell of Example 5. The discharge time was 17.5 hours. Example 9 The experiment of Comparative Example 7 was repeated using the cell of Example 6. The discharge time was 21 hours.

Claims: A method of making a solid state electrochemical cell comprising the steps of providing an alkali metal anode layer, a solid ionically conducting electrolyte layer, and a cathode/current collector layer, with said electrolyte layer interposed between said alkali metal anode layer and said cathode/current collector layer; said cathode/current collector layer being produced by taking an electrically conductive substrate having a plurality of surface voids as a consequence of its physical form, being a mesh, a woven or non-woven fabric, a foamed substrate or a carbon material of fibre or fibril laminate form of ultrahigh surface area, or being provided with surface voids by etching or electrodeposition applied to a film or foil, and wet coating a composition comprising a compound suitable for an intercalation process, an electrically conductive filler, preferably carbon particles,and a curable ionically conductive electrolyte on to the surface of said substrate which in the finished cell faces said electrolyte layer and curing said composition in situ so as substantially completely to fill said voids and so that the composition is tightly adhered to said substrate in the said voids. A method according to Claim 1, wherein said anode layer comprises lithium foil, a metal foil coated with a layer of lithium or a lithium alloy. A method according to Claim 1 or Claim 2, wherein said electrolyte layer comprises a layer of a solid solution of an ionizable alkali metal salt or an alkaline earth salt and an ionically conductive polymeric material. A method according to Claim 3, wherein said polymeric material contains a repeating unit selected from: wherein R is hydrogen or a group Ra, -CH₂ORa, -CH₂OReRa, -CH₂N(CH₃)₂, in which Ra is an alkyl group containing 1 to 16 carbon atoms and preferably 1 to 4 carbon atoms or a cycloalkyl group containing 5 to 8 carbon atoms, and Re is an ether group of formula -CH₂-CH₂Op- wherein p is a number from 1 to 100, preferably 1 or 2; wherein R' is Ra, or ReRa, as defined above; and wherein Re and Ra are as defined above. A method according to Claim 3, wherein said polymeric material comprises polyethylene oxide. A method according to Claims 3, 4 or 5, wherein said salt is a salt of a metal cation selected from Li⁺, Na⁺, K⁺, Mg²⁺,Ca²⁺ and NH 4 + , and an anion selected from I⁻, C10 4 - , BF 4 - , AsF 6 - , CF₃SO 3 - , CF₃CO 3 - , B₁₂H 12 2- , B₁₀Cl 10 2 - , and BZ 4 - , where Z is C₆H₅, an alkyl chain or an aryl chain, said salt cation and said salt anion being maintained in stoichiometric amounts. A method according to any preceding claim, wherein said compound suitable for an intercalation process is selected from V₆O₁₃, MoO₂, MnO₂, V₂O₅, TiS₂, MoS₃ , Cr₃O₆, Li x V₃O₈, V₃O₈, VS₂, NbSe₂, FeOCl, CrOBr, FeS, NiS, Co0, Cu0. A method according to any preceding claim, wherein said ionically conductive electrolyte of said cathode composition comprises a polymer, preferably comprising acrylated polyethylene oxide, the polymer containing a solid solution of an ionizable alkali metal salt or alkaline earth salt. A method according to any preceding claim, wherein said substrate comprises a substrate in the form of an etched foil or electrodeposited film. A method according to any preceding claim, wherein the material of said substrate is selected from carbon, copper, aluminium, nickel, steel, lead, iron and combinations thereof.

Inventors: BLONSKY PETER MILLER, FAUTEUX DENIS GASTON, MOORE MICHAEL JOSEPH, BLONSKY, PETER MILLER, FAUTEUX, DENIS GASTON, MOORE, MICHAEL JOSEPH
Applicants: MHB JOINT VENTURE
Application year: 1990
Main classification: H01M4
IPC codes: H01M4, H01M10