Conductive additive and discharge promotor mixture for reducing cell swelling in alkali metal electrochemical cells

Abstract: An electrode comprising acetylene black or carbon black carbonaceous diluent having a surface area less than about 100 m 2 /gram mixed with graphite and a charge transfer active material to provide an electrode active admixture, is described. The carbonaceous diluent/graphite blend increases the charge transfer capability within the electrode while exhibiting diminished cell swelling in comparison to high surface area carbonaceous diluents. A preferred carbonaceous diluent is SHAWINIGAN BLACK® carbon.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the conversion of chemical energy to electrical energy, and more particularly to a blend of discharge promoter additives consisting essentially of a relatively low surface area carbonaceous diluent and graphite mixed with a charge transfer active material to provide an electrode admixture particularly useful as a cathode in an alkali metal electrochemical cell. The low surface area carbonaceous diluent/graphite mixture of the present invention increases the charge transfer capability within the electrode while exhibiting diminished cell swelling in comparison to high surface area carbonaceous diluents, whether used alone or with graphite. 2. Prior Art It has been documented that certain types of cell chemistries swell during discharge. Such swelling has been attributed to several factors. For example, one of the problems encountered in the discharge of metal oxide cells such as manganese dioxide cells is that the casing can swell from gas production. U.S. Patent No. 5,308,714 to Crespi teaches that the inclusion of minor amounts of V 6 O 13 mixed with the cathode material in a Li/MnO 2 cell retards the formation of gases normally attributed to moisture from manganese dioxide, which is highly hygroscopic. In addition to moisture derived gassing, swelling in metal, metal oxide, metal sulfide and mixed metal oxide cells has been found to be related to the type of carbonaceous diluent used in the cathode mix. Specifically, the swelling of silver vanadium oxide cells containing only low surface area carbonaceous diluents and graphite according to the present invention is less than in cells of a similar chemistry containing at least some high surface area carbonaceous diluent material. Further, the discharge performance of cells including a relatively low surface area carbonaceous diluent and graphite in the cathode mix as the discharge promoter components according to the present invention is comparable to cells of a similar cathode chemistry containing a relatively high surface area carbonaceous diluent, whether with or without graphite. This is an unexpected result because of the surface area differences. Cathode mixes comprising 2% graphite and 1% carbon black are disclosed in US 5 569 558. However US 5 569 558 does not disclose that the carbon black has a relatively low surface area. SUMMARY OF THE INVENTION The object of the present invention is, therefore, to improve the discharge swelling characteristics of both primary and secondary electrochemical cells comprising a solid charge transfer active material which is a mixed metal oxide material and which has a relatively low surface area carbonaceous diluent and graphite as discharge promoter components blended therewith. It is also an object of the present invention to provide a nonaqueous electrochemical cell that is particularly advantageous for implantable medical applications due to its reduced case swelling during discharge. These and other objects are accomplished by the provision of an electrochemical cell. The low surface area carbonaceous diluent preferably has a surface area of less than about 75 m 2 /gram. According to the present invention, the discharge performance of a cell comprising a cathode electrode including a minor amount of a relatively low surface area carbonaceous diluent and a greater amount of graphite as the sole discharge promoter components is comparable to those containing a relatively high surface area carbonaceous diluent, with or without graphite, with the added benefit that swelling is reduced during discharge. As used herein, the terms carbonaceous conductive diluent or conductive diluent mean both carbon black and acetylene black. Acetylene black is a carbonaceous material that is prepared by the formation of polyaromatic macromolecules in the vapor phase. The macromolecules are then converted to the product material by burning the gaseous hydrocarbons in a limited supply of air at about 1,000°C. Carbon black is formed by nucleation of the vapor phase macromolecules into droplets, which are then converted to the product by burning the liquid hydrocarbons in a limited supply of air at about 1,000°C. These and other aspects of the present invention will become more apparent to those skilled in the art by reference to the following description. DETAILED DESCRIPTION OF THE INVENTION It has been well documented that carbonaceous additives are useful as conductive diluents when mixed with solid electrode active materials, such as metals, metal oxides, metal sulfides, mixed metal oxides and carbonaceous materials, for the purpose of aiding in the discharge rate capability of the charge transfer active materials. Discharge rate capability is enhanced because the carbonaceous materials provide increased surface area in the electrode where charge transfer can take place. Thus, solid electrode components for incorporation into a cell according to the present invention include a solid charge transfer active material or a solid electrode active material mixed with at least one relatively low surface area discharge promoter component or conductive diluent and graphite. The conductive diluent of the present invention is selected from the group consisting of carbon black and acetylene black. While more than one type or grade of conductive diluent can be mixed with graphite and the electrode active material, according to the present invention all of the conductive diluents including the graphite must have a total internal and external surface area less than about 100 m 2 /gram. More particularly, the preferred conductive diluent according to the present invention consists substantially of discrete, connected carbonaceous particles of acetylene black having a particle size diameter between about 0.02 to 0.10 microns, and a total external and internal surface area less than about 100 m 2 /gram, more preferably less than about 75 m 2 /gram. A most preferred carbonaceous diluent is an acetylene black material available from Chevron U.S.A. Inc. under the trademark SHAWINIGAN BLACK®, commonly referred to as "SAB". This material has a total external and internal surface area of about 55 to 75 m 2 /gram by the BET method. Almost all of the surface area of the preferred conductive diluent is external so that the conductive material has a relatively low porosity. The SAB conductive diluent has about 99.3% carbon and about 0.6% volatiles, and a resistivity of about 0.035 ohm/inch 3 to about 0.05 ohm/inch 3 , making the carbonaceous material an excellent conductor. SHAWINIGAN BLACK has the following typical physical properties: Typical Properties Acetylene Black (Shawinigan ) Surface area (m 2 /g) 67 Particle diameter (µm) 43 L c (Å) 31 Ash content (wt%) <0.05 Organic extract (wt%) 0.04 ASV (cm 3 acetone/5 g) 29 Density (kg/m 3 ) 70 Other materials commonly referred to as carbon black and acetylene black are also beneficial in the present invention as long as their surface area is less than about 100 m 2 /gram, and more preferably less than about 75 m 2 /gram. For the purpose of the present invention, while graphite is a carbonaceous based material, it is not considered to be a "carbonaceous conductive diluent", but is a distinct discharge promoter material that is mixed with the conductive diluent and the charge transfer active material to provide an electrode. Preferably about 1 to 10 weight percent of the low surface area carbonaceous diluent is mixed with graphite and the electrode active material to provide an electrode component. Graphite as that term is used in the present application is generally referred to as artificial graphite produced by heating petroleum to remove volatiles and then mixing the resultant with coal-tar pitch. The mixture is consolidated and shaped by molding or extruding to produce a "green body." The green body is then heated to about 1,000°C in a nonoxidizing atmosphere to expel the volatile constituents from the pitch. The resulting material is an amorphous carbon that consists of petroleum-coke particles held together by a porous pitch residue. In the final step, carbon is transformed to graphite by heat treatment at 2,500°C to 3,000°C. The resulting artificial graphite product has the following physical properties: Physical Property Artificial Graphite Bulk density (g/cm 3 ) 1.6 Gas permeability (cm 2 /s) 10 -2 Tensile strength(kg/cm 2 ) 420 Thermal expansion(°C) -1 x 10 6 1-3 Thermal conductivity(cal/cm s • °C) 0.3-0.4 Electrical resistivity (Ω • cm) x10 4 7 Preferably, the graphite is present in the electrode active admixture in a quantity of about 1% to about 10%, by volume, and more preferably about 2 to 8%, by weight. For a more detailed discussion of graphite, reference is made to Carbon-Electrochemical and Physical Properties by Kim Kinoshita of Lawrence Berkeley Laboratory, Berkeley California, published by John Wiley & Sons (1988). Suitable charge transfer active materials or electrode active materials include mixed metal oxides the general formula SM x V 2 O y wherein SM is a metal selected from the Group IB of the Periodic Table of elements and x is about 0.30 to 2.0 and y is about 4.5 to 6.0 in the general formula. By way of illustration, and in no way intended to be limiting, one exemplary cathode active material comprises silver vanadium oxide (SVO) having the general formula Ag x V 2 O y in any one of its many phases, i.e., β-phase silver vanadium oxide having in the general formula x = 0.35 and y = 5.8, γ-phase silver vanadium oxide having in the general formula x = 0.74 and y = 5.37 and ε-phase silver vanadium oxide having in the general formula x = 1.0 and y = 5.5, and combinations and mixtures of phases thereof. Another exemplary composite cathode material includes V 2 O z wherein z ≤ 5 combined with Ag 2 O z wherein z=0 to 1 and CuO z wherein z=0 to 1 to provide the mixed metal oxide having the general formula Cu x Ag y V 2 O z , (CSVO). Thus, this composite cathode active material may be described as a metal oxide-metal oxide-metal oxide, a metal-metal oxide-metal oxide, or a metal-metal-metal oxide and the range of material composition found for Cu x Ag y V 2 O z is preferably about 0.01 ≤ x ≤ 1.0, about 0.01 ≤ y ≤ 1.0 and about 5.01 ≤ z ≤ 6.5. Typical forms of CSVO are Cu 0.16 Ag 0.67 V 2 O z with z being about 5.5 and Cu 0.5 Ag 0.5 V 2 O z with z being about 5.75. The oxygen content is designated by z since the exact stoichiometric proportion of oxygen in CSVO can vary depending on whether the cathode material is prepared in an oxidizing atmosphere such as air or oxygen, or in an inert atmosphere such as argon, nitrogen and helium. Additional cathode active materials include manganese dioxide, lithium cobalt oxide, lithium nickel oxide, copper oxide, titanium disulfide, copper sulfide, iron sulfide, iron disulfide, copper vanadium oxide, carbon and fluorinated carbon, and mixtures thereof. The cathode active material is preferably present in the cathode at about 80 to 99 weight percent. Solid cathode active components for incorporation into a cell according to the present invention may be prepared by rolling, spreading or pressing a mixture of one or more of the above listed electrode active materials, the preferred carbonaceous conductive diluent and graphite onto a current collector with the aid of a binder material. The conductive diluent is preferably present in the electrode active admixture in a minor amount compared to the graphite. Thus, the SAB conductive diluent is present in about 0.5 to 2 weight percent while the graphite is present in about 1 to 3 weight percent. The most preferred formulation is 1 weight percent carbonaceous conductive diluent and 2 weight percent graphite. Preferred binder materials include a powdered fluoro-resin such as powdered polytetrafluoroethylene (PTFE) or powdered polyvinylidene fluoride present at about 1 to about 5 weight percent of the electrode active material. Suitable materials for the cathode current collector include a thin sheet or metal screen, for example, a titanium, stainless steel, aluminum or nickel screen. Cathodes prepared according to the present invention may be in the form of one or more plates operatively associated with at least one or more plates of anode material, or in the form of a strip wound with a corresponding strip of anode material in a structure similar to a "jellyroll". Anode active materials acceptable for use with the present cathode electrode comprise metals selected from Groups IA and IIA of the Periodic Table of the Elements, including lithium, sodium, potassium, calcium, magnesium or their alloys, or any alkali metal or alkali-earth metal capable of functioning as an anode. Alloys and intermetallic compounds include, for example, Li-Si, Li-Al, Li-Mg, Li-B and Li-Si-B alloys and intermetallic compounds. In that case, the anode active material preferably comprises lithium. The form of the anode may vary, but typically, the anode comprises a thin sheet or foil of the anode metal, and a current collector contacted to the anode material. In order to prevent internal short circuit conditions, the cathode of the present invention is separated from the Group IA anode material by a suitable separator material. The separator is of electrically insulative material and the separator material also is chemically unreactive with the anode and cathode active materials and both chemically unreactive with and insoluble in the electrolyte. In addition, the separator material has a degree of porosity sufficient to allow flow therethrough of the electrolyte during the electrochemical reaction of the electrochemical cell. Illustrative separator materials include woven and non-woven fabrics of polyolefinic fibers including polyvinylidine fluoride, polyethylenetetrafluoroethylene, and polyethylenechlorotrifluoroethylene laminated or superposed with a polyolefinic or fluoropolymeric microporous film, non-woven glass, glass fiber materials and ceramic materials. Suitable microporous films include a polytetrafluoroethylene membrane commercially available under the designation ZITEX (Chemplast Inc.), a polypropylene membrane commercially available under the designation CELGARD (Celanese Plastic Company, Inc.) and a membrane commercially available under the designation DEXIGLAS (C.H. Dexter, Div., Dexter Corp.). The electrochemical cell of the present invention further includes a nonaqueous, ionically conductive electrolyte which serves as a medium for migration of ions between the anode and the cathode electrodes during the electrochemical reactions of the cell. The electrochemical reaction at the electrodes involves conversion of ions in atomic or molecular forms which migrate from the anode to the cathode. Thus, nonaqueous electrolytes suitable for the present invention are substantially inert to the anode and cathode materials, and they exhibit those physical properties necessary for ionic transport, namely, low viscosity, low surface tension and wettability. A suitable electrolyte has an inorganic or organic, ionically conductive salt dissolved in a nonaqueous solvent, and more preferably, the electrolyte includes an ionizable alkali metal salt dissolved in a mixture of aprotic organic solvents comprising a low viscosity solvent and a high permittivity solvent or, a single solvent. The ionically conductive salt serves as the vehicle for migration of the anode ions to intercalate or react with the cathode active material. Preferably the ion-forming alkali metal salt is similar to the alkali metal comprising the anode. Suitable nonaqueous electrolytes are comprised of an inorganic salt dissolved in a nonaqueous solvent and more preferably an alkali metal salt dissolved in a mixture of aprotic organic solvents comprising a low viscosity solvent including. organic esters, ethers and dialkyl carbonates, and mixtures thereof, and a high permittivity solvent including cyclic carbonates, cyclic esters and cyclic amides, and mixtures thereof. Suitable nonaqueous solvents are substantially inert to the anode and cathode electrode materials and preferred low viscosity solvents include tetrahydrofuran (THF), methyl acetate (MA), diglyme, triglyme, tetraglyme, dimethyl carbonate (DMC), diethyl carbonate (DEC), dipropyl carbonate (DPC), methyl ethyl carbonate (MEC), methyl propyl carbonate (MPC), ethyl propyl carbonate (EPC), 1,2-dimethoxyethane (DME), and others. Preferred high permittivity solvents include propylene carbonate (PC), ethylene carbonate (EC), butylene carbonate (BC), acetonitrile, dimethyl sulfoxide, dimethyl formamide, dimethyl acetamide, γ-butyrolactone (GBL) and N-methyl-pyrrolidinone (NMP) and others. Known lithium salts that are useful as a vehicle for transport of alkali metal ions from the anode to the cathode and back again include LiPF 6 , LiBF 4 , LiAsF 6 , LiSbF 6 , LiClO 4 , LiAlCl 4 , LiGaCl 4 , LiC(SO 2 CF 3 ) 3 , LiN(SO 2 CF 3 ) 2 , LiSCN, LiO 3 SCF 2 CF 3 , LiC 6 F 5 SO 3 , LiO 2 CF 3 , LiSO 3 F, LiB(C 6 H 5 ) 4 and LiCF 3 SO 3 , and mixtures thereof. Suitable salt concentrations typically range between about 0.8 to 1.5 molar, and in the preferred electrochemical cell comprising the Li/SVO couple, the preferred electrolyte is 1.0M to 1.2M LiAsF 6 in a 50:50, by volume mixture of DME:PC. The relatively low surface area conductive diluent of the present invention is also useful in an alkali metal ion cell. Such rechargeable cells are typically constructed in a discharged state. The alkali metal ions, such as lithium, comprising a lithiated cathode are then intercalated into a carbonaceous anode by applying an externally generated electrical potential to recharge the cell. The applied recharging electrical potential serves to draw the alkali metal ions from the cathode including the low surface area conductive diluent according to the present invention, through the separator via the electrolyte and into the carbonaceous material of the anode to saturate the same. The cell is then provided with an electrical potential and is discharged in a usual manner. Particularly useful lithiated materials that are stable in air and readily handled include lithiated nickel oxide, lithiated manganese oxide, lithiated cobalt oxide and lithiated mixed oxides of cobalt with nickel or tin. The more preferred oxides include LiNiO 2 , LiMn 2 O 4 , LiCoO 2 , LiCo 0.92 Sn 0.08 O 2 and LiCo 1-x Ni x O 2 . The preferred form of the electrochemical cell is a case-negative design wherein the anode/cathode couple is inserted into a conductive metal casing such that the casing is connected to the anode current collector in a case-negative configuration, as is well known to those skilled in the art. A preferred material for the casing is titanium although stainless steel, nickel and aluminum are also suitable. The casing header comprises a metallic lid having a sufficient number of openings to accommodate the glass-to-metal seal/terminal pin feedthrough for the cathode electrode. The anode electrode is preferably connected to the case or the lid. An additional opening is provided for electrolyte filling. The casing header comprises elements having compatibility with the other components of the electrochemical cell and is resistant to corrosion. The cell is thereafter filled with the electrolyte solution described hereinabove and hermetically sealed such as by close-welding a stainless steel plug over the fill hole, but not limited thereto. The cell of the present invention can also be constructed in a case-positive design. The following example describes the manner and process of carrying out the present invention in an electrochemical cell, and this example sets forth the best mode contemplated by the inventors of carrying out the invention, but it is not to be construed as limiting. EXAMPLE I Thirty-six prismatic lithium/silver vanadium oxide cells were built having a central cathode flanked on either side by the lithium anode. The cells were designated with Serial Nos. 70718 to 70753. The cells were divided into four groups as follows: Group I according to the present invention contained, by weight, about 94% silver vanadium oxide, 3% polytetrafluoroethylene (PTFE) binder, about 1% Chevron SHAWINIGAN BLACK® carbon and about 2% graphite; Group II contained, by weight, 94% SVO, 3% PTFE and 3% graphite with no carbonaceous diluent; Group III had, by weight, about 95% silver vanadium oxide, 3% PTFE and 2% KETJENBLACK®, a relatively high surface area carbon available from Akzo Chemicals B.V., but no graphite; and Group IV served as a control. The control cell group included cathode electrodes containing, by weight, about 94% silver vanadium oxide, 3% PTFE, 2% graphite and 1% KETJENBLACK®. Table 1 sets forth the proportion of materials, by weight, in the various cell groups and Table 2 presents some of the physical characteristics of the two carbonaceous diluents used to construct the cells discussed above: Cell Group SVO PTFE Carbon Graphite I 94 3 1 (SAB) 2 II 94 3 0 3 III 95 3 2 (KETJ) 0 IV 94 3 1 (KETJ) 2 Carbon Surface Area, m 2 /g mean particle size, µm bulk density, g/cm3 KETJENBLACK® 800-1000 ∼30 -0.145 SHAWINIGAN BLACK® 60-70 ∼40 ∼0.0945-0.1026 Three cells from each group were assigned to accelerated, pulse discharge or 3.01 KΩ or 5 KΩ constant resistance discharge. The thicknesses of the cells were measured periodically throughout discharge, and the discharge capacity to various voltage cut-offs and the change in cell thickness from before to after completion of discharge are presented in Tables 3, 4 and 5, respectively. Accelerated discharge in this example comprised application of a train of pulses to the respective cells each half hour. Each train consisted of four 2.0 amp pulses of 10 seconds duration with 15 seconds rest between each pulse. The discharge capacity to various voltage cut-offs and the change in cell thickness after completion of discharge for those cells subjected to accelerated pulse discharge are presented in Table 3. mAh to: Cell Group Serial No. 2V 1.7V 1.5V Total Δ Thickeness in. 70719 1336 1738 1835 -0.002 I 70728 1469 1779 1876 -0.005 70730 1400 1741 1847 -0.002 70720 1096 1656 1781 -0.002 II 70744 1227 1720 1824 -0.002 70750 41 594 789 -0.002 70724 1596 1787 1864 +0.017 III 70733 1637 1819 1894 +0.014 70745 1624 1805 1883 +0.017 70731 1479 1785 1871 +0.002 IV 70732 1434 1788 1880 +0.001 70734 1480 1798 1898 -0.001 For those cells that were subjected to accelerated pulse discharge, thickness changes from before to after testing for the Group I cells containing a minor amount of the low surface area SHAWINIGAN BLACK® carbon and a greater amount of graphite, and the Group II cells containing all graphite were negative (cells got thinner by 0.002 in. to 0.005 in.) while the change in thickness in the control cells ranged from -0.001 in. to +0.002 inches. The Group III cells containing all high surface area KETJENBLACK® carbon increased in thickness by 0.014 in. to 0.017 in. The poor performance of the cell indicated as Serial No. 70750 was unexplained. The capacity to various voltage cut-offs and the change in cell thickness after completion of discharge for those cells subjected to the 3.01 KΩ constant resistance load are presented in Table 4. mAh to: Cell Group Serial No. 2V 1.7V 1.5V Total Δ Thickness, in. 70718 2197 2415 2486 +0.054 I 70726 2196 2413 2487 +0.057 70738 2207 2421 2495 +0.057 70722 2116 2167 2206 +0.033 II 70736 2194 2404 2458 +0.048 70753 2209 2415 2475 +0.053 70721 2222 2436 2550 +0.075 III 70743 2235 2437 2562 +0.070 70751 2234 2435 2562 +0.073 70735 2214 2421 2571 +0.078 IV 70741 1967 2171 2323 +0.082 70749 2230 2430 2563 +0.072 All groups of cells discharged under the 3 KΩ constant resistance load showed an increase in thickness concurrent with reaching 2.0 V under load. The Group III, all KETJENBLACK® cells showed a gradual increase throughout life while the other groups did not swell until their voltages reached 2.0 V. Swelling was greatest in the all KETJENBLACK® carbon and control cells (≥0.072") and least in the graphite cells (≤0.053") of Group II. Both cathode swelling and electrolyte decomposition (gas formation) were deemed responsible for this. Electrolyte decomposition occurred in all the cells regardless of the type of carbonaceous diluent used. The discharge capacity of the Group I, SHAWINIGAN BLACK®/graphite cells is not statistically significantly different in comparison to the Group II, graphite cells, the Group III, KETJENBLACK® cells and the Group IV, control cells discharged under the 3.01 KΩ constant resistance load. The capacity to various voltage cut-offs and the change in cell thickness after completion of discharge for those cells subjected to the 5 KΩ constant resistance load are presented in Table 5. mAh to: Cell Group Serial No. 2V 1.7V 1.5V Total Δ Thickness, in. I 70725 2278 2441 2531 0.072 70746 2259 2420 2526 0.075 70748 2314 2481 2582 0.063 II 70739 2247 2462 2516 0.065 70740 2261 2425 2504 0.069 70742 2262 2425 2501 0.066 III 70729 2295 2470 2588 0.070 70747 2317 2488 2615 0.064 70752 2284 2462 2592 0.069 IV 70723 2285 2454 2579 0.086 70727 2277 2446 2589 0.079 70737 2258 2427 2583 0.078 For those cells discharged under the 5 KΩ constant resistance load, all of the cell groups showed an increase in thickness concurrent with reaching 2.0 V under load. The Group III, all KETJENBLACK® carbon cells showed a gradual increase throughout discharge while the other cell groups did not swell until their voltages reached 2.0 V. Swelling was greatest in the control cells of Group IV which recorded increases in thickness of about 0.078 in. to 0.086 in. The cells in Group I having the SHAWINIGAN BLACK® carbon diluent and graphite according to the present invention swelled about 0.063 in. to 0.075 in., the Group III cells containing the KETJENBLACK® carbon swelled 0.064 in. to 0.070 in. and the Group II cells having graphite but no carbon swelled about 0.065 in. to 0.069 in. Again, electrolyte decomposition (as evidenced by gas release upon case violation) occurred in all the cells regardless of the type of carbonaceous diluent used. The discharge capacity of the Group I, SHAWINIGAN BLACK®/graphite cells is not statistically significantly different in comparison to the Group II, graphite cells, the Group III, KETJENBLACK®/graphite cells and the Group IV, control cells discharged under the 5 KΩ constant resistance load. The results of this example clearly establish that the discharge performance of cells including a relatively low surface area carbonaceous diluent and graphite as the discharge promoter components in the cathode mix according to the present invention is comparable to cells of a similar cathode chemistry containing at least some of a relatively high surface area carbonaceous diluent. However, the cell swelling attributed to the discharge promoter component is markedly decreased when only a low surface area carbonaceous diluent along with graphite is provided in the cathode mix according to the present invention. It is appreciated that various modifications to the inventive concepts described herein may be apparent to those skilled in the art without departing from the scope of the present invention defined by the hereinafter appended claims.

Claims: An electrochemical cell which comprises: (a) an anode comprising an alkali metal; (b) an electrode, configured as a cathode, comprising: (i) an electrode active material selected from copper silver vanadium oxide, copper vanadium oxide, and silver vanadium oxide; (ii) graphite; and (iii) at least one carbonaceous conductive diluent having a surface area less than about 100 m 2 /gram; wherein the carbonaceous conductive diluent/graphite mixture increases the charge transfer capability within the electrode while exhibiting diminished swelling during discharge; and (c) an electrolyte activating and operatively associating with the anode and the cathode. The cell according to Claim 1 wherein the carbonaceous conductive diluent is selected from carbon black, acetylene black, or mixtures thereof. The cell according to Claim 1 or Claim 2 wherein the carbonaceous conductive diluent consists substantially of discrete, connected carbonaceous particles of acetylene black. The cell according to Claim 3 wherein the particles have a diameter of 0.02 µm to 0.10 µm. The cell according to any one of Claims 1 to 4 wherein the carbonaceous conductive diluent has a surface area of 55 to 75 m 2 /gram. The cell according to any one of Claims 1 to 5 wherein the carbonaceous conductive diluent has a total external and internal surface area of 55 to 75 m 2 /gram by the BET method, about 99.3% carbon and about 0.6% volatiles, a resistivity of about 2.19 ohm/m 3 (0.035 ohm/inch 3 ) to about 3.13 ohm/m 3 (0.05 ohm/inch 3 ), particle diameter of about 43 µm, L c (Å) of about 31, ash content of less than about 0.05 weight percent, organic extract of about 0.04 weight percent, absorption stiffness value of about 29 cm 3 acetone/5 grams and a density of about 70 kg/m 3 . The cell according to any one of Claims 1 to 6 wherein the carbonaceous conductive diluent is present in the electrode at 1% to 10%, by weight. The cell according to any one of Claims 1 to 7 wherein the graphite is present in the electrode at 2 to 8%, by weight. The cell according to any one of Claims 1 to 8 wherein the cathode includes a current collector selected from titanium, aluminium, stainless steel, nickel, or mixtures thereof. The cell according to any one of Claims 1 to 9 wherein the anode comprises lithium. The cell according to any one of Claims 1 to 10 further including a casing selected from nickel, titanium, stainless steel, aluminum, or mixtures thereof. The cell according to any one of Claims 1 to 11 wherein the anode contacts the casing in a case-negative configuration. The cell according to any one of Claims 1 to 12 wherein the electrolyte solution, operatively associated with the anode and the cathode, comprises an ion-forming alkali metal salt dissolved in a nonaqueous solvent, and wherein the alkali metal of the salt is the same as the alkali metal comprising the anode. The cell according to any one of Claims 1 to 13 wherein the alkali metal of the anode comprises lithium and the ion-forming alkali metal, salt comprising the electrolyte solution is selected from LiPF 6 , LiAsF 6 , LiSbF 6 , LiBF 4 , LiClo 4 , LiAlCl 4 , LiGaCl 4 , LiC(SO 2 CF 2 ) 3 , LiN(SO 2 CF 3 ) 2 , LiSCN, LiO 3 SCF 2 CF 3 , LiC 6 F 5 SO 3 , LiO 2 CF 3 , LiSO 3 F, LiB(C 6 H 5 ) 4 , LiCF 3 SO 3 , or mixtures thereof. The cell according to any of Claims 1 to 14 wherein the nonaqueous solvent comprises an organic solvent selected from tetrahydrofuran, methyl acetate, diglyme, triglyme, acetonitrile, dimethyl sulfoxide, dimethyl formamide, dimethyl acetamide, diethyl carbonate, propylene carbonate, ethylene carbonate, butylene carbonate, tetraglyme, dimethyl carbonate, dipropyl carbonate, methyl ethyl carbonate, methyl propyl carbonate, ethyl propyl carbonate, 1, 2-dimethoxymethane, γ-butyrolacetone and N-methyl-pyrrolidinone, or mixtures thereof. A cell according to anyone of claims 1 to 8 wherein the cathode is configured as an alkalated cathode and the anode comprises material capable of intercalating an alkali metal. The cell according to Claim 16 wherein the cathode active material is selected from alkalated nickel oxide, alkalated manganese oxide, alkalated cobalt oxide and alkalated mixed oxides of cobalt with nickel or tin, or mixtures thereof. The cell according to Claim 16 or Claim 17 wherein the electrolyte solution, operatively associated with the anode and the cathode, comprises an ion-forming alkali metal salt dissolved in the nonaqueous solvent, and wherein the alkali metal of the salt is the same as the alkali metal comprising the alkalated cathode. A method of providing the electrochemical cell according to any preceding claim which comprises the steps of: (a) providing a casing; (b) providing an anode inside the casing; (c) providing the electrode configured as a cathode, inside the casing; (d) activating and operatively associating the anode and the cathode by filling an electrolyte into the casing. The method according to Claim 19 including providing the graphite present in the cathode at 1% to 10%, by weight. The method according to Claim 19 or Claim 20 including selecting the cathode active material from manganese dioxide, copper silver vanadium oxide, copper vanadium oxide, silver vanadium oxide, titanium disulfide, copper oxide, copper sulfide, iron sulfide, iron disulfide, carbon, fluorinated carbon, or mixtures thereof.

Inventors: TAKEUCHI ESTHER S, THIEBOLT WILLIAM C III, TAKEUCHI, ESTHER S., THIEBOLT, WILLIAM C, III
Applicants: GREATBATCH W LTD, WILSON GREATBATCH LTD.
Application year: 1998
Main classification: H01M4
IPC codes: H01M4, H01M10, H01M6