A NON-AQUEOUS ELECTROLYTE SYSTEM FOR USE IN BATTERIES, CAPACITORS OR ELECTROCHROMIC DEVICES AND A METHOD FOR THE PREPARATION THEREOF

Abstract: A new non-aqueous electrolyte system for use in batteries, capacitors or electrochromic displays, and consisting essentially of an alkali or ammonium salt, a solvent mixture, and optionally a polymer is disclosesd. The new electrolyte system is characterised in that the solvent mixture comprises a mixture of ethylene carbonate (EC) and gamma -valerolactone ( gamma -VL), optionally containing one or more additional solvents selected from other organic carbonates, other lactones, esters and glymes, said system optionnaly being confined in a separator. The electrolyte system can be applied in a broad voltage range, has a conductivity higher than 10<-3> S/cm at room temperature, and shows a high stability against reduction. The improved stability towards reduction is mirrored in a cycling efficiency which is superior to the cycling efficiency of known non-aqueous electrolyte systems.

Description: A non-aqueous electrolyte system for use in batteries, ca¬ pacitors or electrQchroπiic devices and a method for the preparation thereof This invention is related to a non-aqueous electrolyte sys¬ tem for use in batteries, capacitors or electrochromic de¬ vices, said system essentially consisting of an alkali or ammonium salt, a solvent mixture and optionally a polymer. Liquid, solid and immobilized non-aqueous electrolytes are of considerable interest for use in lithium batteries, su¬ percapacitors and other electrochemical devices. Recently, lithium secondary batteries have been developed based on lithium insertion materials for both the negative electrode and the positive electrode. Such electrochemical cells have a cell voltage in excess of 4V in the charged state and an energy density of more than 100 Wh/kg. Simi¬ larly for the recently developed supercapacitor cells, voltages higher than 3V give considerable improvement with respect to the energy storage capability. However, elec¬ trolyte compositions used in these devices are traditio¬ nally limiting the device performance because of low ionic conductivity and low electrochemical stability. The de- mands for electrolytes in batteries and supercapacitors have been sufficiently fulfilled only with few organic carbonates or in particular with mixtures thereof. US 5 192 629 of Bell Communication Research Inc. describes an electrolyte system comprising a solution of LiPF 6 in a mixture of dimethyl carbonate and ethylene carbonate. EP 541 889 of Sanyo Electric Co. describes for lithium-ion graphite-based batteries the combination of a separator with a liquid electrolyte comprising one or more of the solvents ethylene carbonate, propylene carbonate, lactones and sulfolanes. US 5 240 790 of Alliant Techsystems Inc. describes the use of a polyacrylonitrile-based gelled polymer system, which includes as an immobilised liquid phase a ternary plasti- cifier mixture of ethylene carbonate, γ-butyrolactone and polyethylene glycol dimethyl ether, in lithium-based elec¬ trode batteries. US 5 326 657 of Nippon Oil Co. describes a polymeric solid ionic electrolyte having good mechanical properties. The polymeric solid electrolyte is a radiation crosslinked network based on a polyfunctional acrylate compound, con- taining a non-aqueous organic solvent and an alkali metal and/or an ammonium salt. EP 651 455 of Matsushita Electrical Industrial Co Ltd. de¬ scribes the use of a separator based on polyethylene and/or polypropylene to prevent lithium secondary batteri¬ es from shortcircuiting. Although electrolyte systems showing high conductivity and which are stable against oxidation are known, there still exists a need for an electrolyte system which in addition to said high conductivity and high oxidation stability display a high stability against reduction. Accordingly, it is an object of the invention to provide a non-aqueous electrolyte system for use in batteries, capa¬ citors or electrochromic devices (including so-called "smart windows") which can be applied in a broad voltage range, which has a conductivity higher than 10 "3 S/cm at room temperature, and which shows a high stability against reduction. Now it has been found that this object is accomplished by an electrolyte system consisting essentially of an alkali or ammonium salt, a solvent mixture, and optionally a po¬ lymer, wherein said solvent mixture comprises a mixture of ethylene carbonate and γ-valerolactone, optionally contai¬ ning one or more additional solvents selected from other organic carbonates, other lactones, esters and glymes, said system optionally being confined in a separator. Whereas the pure γ-valerolactone is electrochemically sta¬ ble against coke and graphite, the passivation layer for¬ med upon reaction with the lithium containing negative electrode structures is poor, the lithium conductivity is poor, the reaction product is neither thermodynamically nor kinetically stable, and the cell balance is severely distorted as large amounts of active material is consumed in the passivation reaction. In contrast, the ethylene carbonate displays good proper- ties of the passivation layer formed, high conductivity, stability and low materials consumption. Pure ethylene carbonate, however, is solid at ambient temperature. Both of the materials γ-valerolactone and ethylene carbonate show good electrochemical stability vs. the cathode mate- rials of lithium transition metal oxide type. Surprisingly however, the mixture of γ-valerolactone and ethylene carbonate has been found to combine the preferred characteristics of the two individual components and fur- thermore results in high electrochemical stability against the negative electrode and formation a high performance passivation layer. Moreover, the highly conductive electrolyte system of the invention allows operation of rechargeable lithium batte- ries with cell voltages above 4V and supercapacitors with cell voltages above 3V. Compared to the mixture of γ-butyrolactone and ethylene- carbonate known from US 5 240 790, the mixture of ethylene carbonate and γ-valerolactone is a superior solvent mixtu¬ re for high performance electrolyte applications, since said known and structurally close mixture displays poorer electrochemical stability against the negative electrode of the electrochemical system, although both mixtures shown an oxidation stability and conductivity which is non-restictive for their application in the said electro¬ chemical systems. The improved stability towards reduction is mirrored in the cycling efficiency of the ethylene carbonate/γ- valerolactone mixture, which is superior to the cycling efficiency of the ethylene carbonate/γ-butyrolactone mix¬ ture. In particular, a lower irreversible loss of active material is observed for the former mixture, the capacity of the electrochemical cell being sustained through a high number of cycles. The ethylene carbonate and γ-valerolactone are preferably present in the solvent mixture in a relative molar ratio of from 20:80 to 80:20. The solvent mixture is preferably composed of at least 50%, more preferably at least 90% of ethylene carbonate and γ-valerolactone. In an even more preferred embodiment of the invention the solvent mixture of the electrolyte is composed essentially of ethylene carbonate and γ-valerolactone only. In an alternative embodiment of the invention the solvent mixture comprises, in addition to ethylene carbonate and γ-valerolactone, one or more of the following solvents: (a) alicyclic carbonates represented by the following ge- neral formula: wherein each of R lr R 2 . R 3, R 4 , R 5 and R 6 independently re- present hydrogen or C -C 2 alkyl groups and m is an integer equal to 0 or 1, with the proviso that when m is equal to 0, at least one of R 1( R 2 ' and R 6 is different from hy¬ drogen, preferably propylene carbonate; (b) aliphatic carbonates represented by the general formu¬ la R 7 [0C(0)] P 0R 8 , wherein R 7 and R 8 independently represent C 1 -C 4 alkyl groups, and p is an integer equal to 1 or 2, preferably dimethyl carbonate and/or diethyl carbonate; (c) lactones in the form of cyclic esters represented by the general formula: wherein each of R 9 , R 10 , n, ι2 , R i3 , R_ 4 , R_ and R 16 inde- pendently represent hydrogen or C___ 2 alkyl groups and r is an integer equal to 0 or 1, with the proviso that the va¬ lue of r and the nature of the substituents are chosen so as to exclude γ-valerolactone from the definition, prefe¬ rably γ-butyrolactone; (d) esters represented by the formula R 17 [C(0)]0R 18 [0R 19 ] t , wherein each of R 17 , R lβ and R 19 independently represent hy¬ drogen or C 1 -C 2 alkyl groups, and t is an integer from 0 to 2, preferably an acetate, more preferably (2-methoxy- ethyl)-acetate and/or ethyl acetate; (e) glymes represented by the general formula R 2o O(R 2ι O) n R 22 , in which R 20 and R 22 independently represent C^ alkyl groups, R 21 is -(CR 23 R 24 CR 25 R 26 )- wherein R 23 , R 24 , R 25 and R 26 independently each represent hydrogen or C 1 -C 4 alkyl groups, and n is an integer from 2 to 6, preferably 3, R 20 and R 22 preferably being methyl groups, R 23 , R 24 , R 25 and R 26 preferably being hydrogen or C^Cz alkyl groups, more pre¬ ferably hydrogen. Any salt commonly employed as an ion-conductive salt in batteries or capacitors may be used in the electrolyte sy¬ stem according to the invention. Preferably however, the salt is an alkali salt or a quaternary ammonium salt of C10 4 " , CF 3 SO 3 " , AsF 6 " , PF 6 " or BF 4 " , or any mixture of such al¬ kali or ammonium salts, more preferably LiAsF 6 , LiPF 6 , N(Et) 4 PF 6 or N(Bu) 4 PF 6 or any mixtures thereof. In order to provide mechanical integrity of the electroly¬ te, the electrolyte system preferably comprises a cros- slinked or non-crosslinked, advantageously non-crosslin- ked, polymer produced by UV or heat induced polymerisation of monomers or oligomers containing one or more polymeri- sable functional groups, said polymer more preferably be¬ ing a non-crosslinkable polyester, polyurethane, polyether or polyacrylate. The polymer is preferably produced by heat induced polyme¬ risation at a temperature lower than 70°C, performed on an electrolyte precursor containing electrolyte salt, solvent mixture and the above-mentioned monomers or oligomers. The electrolyte system according to the invention is pre¬ ferably incorporated in a separator consisting of a porous structure made from a polymer, preferably polyethylene, polypropylene, polycarbonate or cellulose. The separator acts as a matrix which confines the physical dimensions of the electrolyte system, thereby enabling the production of thin, self-sustaining and uniform electrolyte membranes. The separator is preferably a woven or non-woven structure having a pore size in the range of 10 x 10 nm to 1 x 1 mm and a thickness of 10-100μm, preferably 10-25μm. More spe- cifically, the size of the pores can be as in a micro- porous film (e.g. a Celgard separator) or up to 1 x 1 mm as in a woven net having a mesh of this size. The alkali or ammonium salt is preferably present in a concentration from 0.01M to 2.5M, more preferably 0.1M to 1.5M, in the electrolyte system. The polymer is preferably present in an amount corresponding to from 3% to 95% by weight, preferably 5% to 70% by weight, more preferably 5% to 40% by weight, even more preferably 15% to 40% by weight, relative to the total weight of the electrolyte system. The present invention is furthermore concerned with a simple and economically advantageuos method for the prepa¬ ration of the electrolyte system of the invention, said method comprising mixing the solvents, dissolving the al¬ kali or ammonium salts in the solvent mixture, optionnaly adding a thickening agent to the solution, and optionally adding monomers or oligomers containing one or more poly- merisable functional groups, addition of a UV-photoini- tiator or a heat-initiator, optionally incorporation of the obtained mixture in a separator and UV or heat curing of the monomers or oligomers. In the following table I, some physical data of the ethy- lene carbonate and γ-valerolactone are listed. TABLE I Compound Type Nominal melting boiling formula point (°C) point (°C) ethylene alicyclic C 3 H 4 0 3 38 243 carbonate carbonate γ-valero¬ cyclic C 5 H 8 0 2 -31 207 lactone ester In the following examples preparation of various embodi¬ ments of the non-aqueuos electrolyte system of the inven¬ tion and the manufacture of variuos electrochemical devi¬ ces containing the said electrolyte system is illustrated. EXAMPLE I A I M solution of LiPF 6 in ethylene carbonate/γ-valerolac- tone (1:1 by weight) was prepared by dissolving 13.5 g of LiPF 6 in a mixture of 50 g of ethylene carbonate and 50 g of γ-valerolactone. The conductivity was measured by ac impedance spectroscopy at 65 kHz in an experimental cell with stainless steel electrodes. The conductivity was 8.2 mS/c at 25°C. The electrochemical stability range of the electrolyte was measured by cyclic voltametry at 200 mV/s in the range of 1-6 V vs. Li/Li + , using a Pt-microelectrode having a radius of 5 μm. The oxidation potential was defi¬ ned as the potential at which the current exceeded 3 mA/cm , and was found to be 4.7 V vs. Li/Li + . The reduction behaviour was investigated applying the electrode in cells with Li-intercalating carbon-based negative electrode structures according to example III. EXAMPLE II To a 1M solution of LiPF 6 in a 1:1 mixture mixture of ethy¬ lene carbonate and γ-valerolactone was added 17.3% by weight of polyethylene glycol diacrylate (M.W:508) and 3% by weight of PEO (M.W: 600k). Subsequently, 3% by weight of polymerisation initiator (Darocure 1173) was added. The resulting UV-cured electrolyte had a conductivity of 2 x 10 "3 S/cm at 20°C. EXAMPLE III A rechargeable Li/carbon cell was prepared by laminating together a 25μm thick lithium foil with lOOμm of the elec¬ trolyte of example 1 and a 40μm thick carbon electrode. The carbon electrode was prepared by pressing a mixture of petroleum coke and binder onto a copper foil. The reversi- ble capacity of the resulting cell was 200 mAh/g, and the irreversible loss was 50 mAh/g. The resistance of the cell was constant for more than 100 cycles, 75% of the initial electrode capacity being available after 100 cycles. COMPARATIVE EXAMPLE A A rechargeable Li/carbon cell was prepared in the same manner as described in example III, except from using γ- butyrolactone in stead of γ-valerolactone. The reversible capacity of the resulting cell was 170 mAh/g, and the ir¬ reversible loss was 60 mAh/g. The resistance of the cell increased significantly during the first 10 cycles, 75% of the initial electrode capacity being available after 10 cycles. EXAMPLE IV A lithium ion cell having a graphite negative electrode, a lithium manganese oxide positive electrode and an electro¬ lyte system consisting of 1M LiPF 6 in a mixture of ethylene carbonate and γ-valerolactone was prepared. The resulting cell showed full utilisation of the positive electrode ca¬ pacity. The cell was cycled between 3.2V and 4.2V and dis¬ played 85% of the original capacity after 40 cycles. EXAMPLE V A 1M solution of N(Et) 4 PF 6 in ethylene carbonate/γ- valerolactone (1:1 by weight) was prepared by dissolving 27.5 g of N(Et) 4 PF 6 in 50 g of ethylene carbonate and 50 g of γ-valerolactone. The conductivity was 12.4 mS/cm at 25°C. A capacitor was prepared from two carbon-based poly¬ mer-bound laminates, between which the electrolyte system was sandwiched. The resulting capacitor was cycled between 2,4V and 3.6V for more than 5000 cycles with a constant current of 1.0 mA/cm . EXAMPLE VI To a mixture of 4 g of ethylene carbonate and 3 g of γ- valerolactone was added 1.1 g of LiCF 3 S0 3 , 12.8 g of poly¬ ethylene glycol diacrylate (MW:508) and 4 g of 2-(2- ethoxyethoxy)ethyl acrylate. 1.6% of a photoinitiator (Darocure 1173) was incorporated in the mixture. This mix¬ ture was sandwiched between a W0 3 glass electrode and a counter glass electrode, applying an electrolyte thickness of 1 mm, and subsequently UV cured for 60 s. The resulting smart window was charged, say bleached, and discharged, say colored, for more than 1000 cycles.

Claims: Claims . 1. A non-aqueous electrolyte system for use in batteries, capacitors or electrochromic displays, said system consi sting essentially of: - an alkali or ammonium salt - a solvent mixture, and optionally - a polymer, characterised in that the solvent mixture comprises a mix ture of ethylene carbonate and γ-valerolactone, optional ly containing one or more additional solvents selecte from other organic carbonates, other lactones, esters an glymes, said system optionally being confined in a separa tor. 2. An electrolyte system according to claim 1, in whic ethylene carbonate and γ-valerolactone are present in th solvent mixture in a relative molar ratio of from 20:80 t 80:20. 3. An electrolyte system according to claim 1 or 2, i which the solvent mixture is composed of at least 50%, preferably at least 90% of ethylene carbonate and γ-va¬ lerolactone, more preferably composed essentially of ethy¬ lene carbonate and γ-valerolactone only. 4. An electrolyte system according to claim 1 or 3, in which in addition to ethylene carbonate and γ-valerolac¬ tone comprises one or more of the following solvents: (a) alicyclic carbonates represented by the following ge¬ neral formula: wherein each of R l f R 2 , R 3 , R 4 , R 5 and R 6 independently re¬ present hydrogen or C- t -C-j alkyl groups and m is an integer equal to 0 or 1, with the proviso that when m is equal to 0, at least one of R_ , R 2 , R 5 and R 6 is different from hy¬ drogen, preferably propylene carbonate; (b) aliphatic carbonates represented by the general formu¬ la R 7 [OC(0)] p OR 8 , wherein R 7 and R 8 independently represent C x -C 4 alkyl groups, and p is an integer equal to 1 or 2, preferably dimethyl carbonate and/or diethyl carbonate; (c) lactones in the form of cyclic esters represented by the general formula: 0 wherein each of R 9 , R 10 , R u , R i2 , R_ 3r R_. 4 , Rι 5 and R 16 inde pendently represent hydrogen or C^. alkyl groups and r i an integer equal to 0 or 1, with the proviso that the va lue of r and the nature of the substituents are chosen s as to exclude γ-valerolactone from the definition, prefe rably γ-butyrolactone; (d) esters represented by the formula R 17 [C(0)]0R lβ [0R 19 ] t , wherein each of R 17 , R 18 and R 19 independently represent hy¬ drogen or Ci-C;-, alkyl groups, and t is an integer from 0 t 2, preferably an acetate, more preferably (2-methoxy- ethyl)-acetate and/or ethyl acetate; (e) glymes represented by the general formula R 20 0(R 2l O) n R 22 , in which R 20 and R 22 independently represent C^ alkyl groups, R 21 is -(CR 23 R 24 CR 25 R 26 )- wherein R 23 , R 24 , R 25 and R 2 independently each represent hydrogen or C x -C 4 alkyl groups, and n is an integer from 2 to 6, preferably 3, R 2 and R 22 preferably being methyl groups, R 23 , R 24 , R 25 and R 2 preferably being hydrogen or C- L -C J alkyl groups, more pre¬ ferably hydrogen. 5. An electrolyte system according any of the preceding claims, in which said salt is an alkali salt or a quater¬ nary ammonium salt of C10 4 " , CF 3 S0 3 " , AsF 6 " , PF 6 " or BF 4 " , or any mixture of such alkali or ammonium salts, preferably LiAsF 6 , LiPF 6 , N(Et) 4 PF 6 or N(Bu) 4 PF 6 or any mixtures there¬ of. 6. An electrolyte system according to any of the preceding claims comprising a crosslinked or non-crosslinked, prefe- rably non-crosslinked, polymer produced by UV or heat in¬ duced polymerisation of monomers or oligomers containing one or more polymerlsable functional groups, said polymer more preferably being a non-cross-linkable polyester, po- lyurethane, polyether or polyacrylate. 7. An electrolyte system according to claim 6, in which the polymer is produced by heat induced polymerisation at a temperature lower than 70°C. 8. An electrolyte system according to any of the preceding claims, said system being confined in a separator consi¬ sting of a porous structure made from a polymer, prefe¬ rably polyethylene, polypropylene, polycarbonate or cellu¬ lose. 9. An electrolyte system according to claim 8, in which said separator is in a woven or non-woven structure having a pore size in the range of 10 x 10 run to 1 x 1 mm. 10. An electrolyte system according to any of the claims 8 and 9, in which said separator has a thickness of 10- lOOμm, preferably 10-25μm. 11. An electrolyte system according to any of the prece¬ ding claims, in which the alkali or ammonium salt is pre- sent in a concentration from 0.01M to 2.5M, preferably 0.1M to 1.5M. 12. An electrolyte system according to any of the prece¬ ding claims, in which the polymer is present in an amount corresponding to from 3% to 95% by weight, preferably 5% to 70% by weight, more preferably 5% to 40% by weight, even more preferably 15% to 40% by weight, relative to the total weight of the electrolyte system. 13. A method for the preparation of an electrolyte system according to each of the preceding claims, comprising mi- xing the solvents, dissolving the alkali or ammonium salt in the solvent mixture and optionnaly adding a thickenin agent to the solution. 14. A method according to claim 13 further comprising ad ding monomers or oligomers containing one or more polyme rlsable functional groupsm, addition of a UV-photoini tiator or a heat-initiator, optionally incorporation o the obtained mixture in a separator and UV or heat curin of the monomers or oligomers. 15. Use of an electrolyte system according to each of th preceding claim in a battery, a capacitor and/or in electrochromic display.

Inventors: CONSIGNY MARINE, WENDSJO AASA, YDE-ANDERSEN STEEN, CONSIGNY, MARINE, WENDSJO, AASA, YDE-ANDERSEN, STEEN
Applicants: CONSIGNY MARINE, DANIONICS AS, WENDSJO AASA, YDE ANDERSEN STEEN, CONSIGNY, MARINE, DANIONICS A/S, WENDSJO, AASA, YDE-ANDERSEN, STEEN
Application year: 1995
Main classification: H01M6
IPC codes: G02F1, H01B1, H01G9, H01M6, H01M10