Abstract:
A solvent of the polymer-salt complex and a non-solvent thereof are added to the solvent used in the polymer synthesis, to provide a lower and an upper phase. The lower phase contains substantially all the polymer in the solvent of the polymer-salt complex. It is separated from the upper phase and the salt is added to the lower phase to constitute a solution of the electrolyte.

Description:
BACKGROUND OF INVENTION 
     1. Field of the Invention 
     The present invention concerns a process for preparing solutions containing the electrolytes used in lithium-polymer batteries of the ACEP type (polymer electrolyte battery). More specifically, the invention is concerned with a process for transferring the polymer directly from the solvent of the polymer synthesis, to the more polar solvent of the polymer-salt complex. Generally, the invention aims at the formation of a ternary solvent mixture including the solvent of the polymer synthesis, the solvent of the polymer-salt complex and a non-solvent of the polymer, and at the achievement of two phases where the polymer is found in the lower phase containing most of the solvent of the polymer-salt complex. 
     2. Description of Prior Art 
     Lithium-polymer electrolyte ACEP batteries are manufactured by superposing three main types of films: a film of a positive electrode containing an electrochemically active material, for example vanadium oxide, a film of an electrolyte consisting of a polymer and a lithium salt, and a film of metallic lithium. Each of these films is between 15 and 50 μm thick, for a total thickness of the elementary film of battery of 100 to 150 μm. About 30 meters of this elementary film 15 cm wide, are typically required to give a battery of 100 Wh. 
     The families of polymers used in the electrolyte films are described in Armand&#39;s U.S. Pat. No. 4,303,748, as well as in more detail in U.S. Pat. Nos. 4,578,326 and 4,357,401, and Canadian Patent No. 1,269,702. For example, they may consist of amorphous copolymers and terpolymers, which may be cross-linkable. These polymers are not presently commercially available, and are mainly synthesized with coordination catalysts of the type described in Vandenberg U.S. Pat. No. 3,205,183 (September 1965). This polymerization may only be carried out in relatively non polar solvents such as ethyl ether or toluene. 
     The polymer-lithium salt mixtures used in the electrolytes and positive electrodes are usually not soluble in these solvents, and more polar ones such as those based on acetonitrile, must be used to solvent-cast the films, a commonly used method for the electrolytes, and the only one for positive electrodes. 
     To switch from the synthesis solution containing only the polymer to the electrolyte solution containing the polymer-lithium salt mixture, the solvents must therefore be changed. One way to proceed consists in precipitating the polymer from the synthesis solution by means of a non-solvent, in drying the precipitate then in re-dissolving the latter in the new solvent, with the lithium salt. The last two steps are long and costly, particularly with polymers of high molecular weights (Mw&gt;100,000). 
     SUMMARY OF INVENTION 
     It is an object of the invention to provide for the transfer of the polymer, directly from its synthesis solvent to the solvent of the polymer-salt complex of the electrolyte, without having to precipitate the polymer and to re-dissolve the polymer in the latter solvent. 
     Another object aims at providing a process for the preparation of solutions of electrolyte for lithium-polymer batteries of the ACEP type, enabling to obtain the polymer directly in a mixture of solvents leading to a more efficient drying of the films of electrolyte and positive electrode during the coating process (azeotropic mixture). 
     Another object of the invention is achieved by adding a solvent of the polymer-salt complex and a non-solvent to the solvent of the polymer synthesis, preferably acetonitrile and heptane when toluene is used as the synthesis solvent. 
     The invention concerns a process for the preparation of a solution of an electrolyte containing a polymer-salt complex as well as a solvent of said complex, said salt being represented by formula M +  X -  where M +   is a cation which is derived from an alkali metal or the ammonium ion and X -  represents an anion of a strong acid. The polymer is derived from at least one monomer comprising at least one heteroatom capable of forming bonds of the donor-receptor type with the cation M + , from a synthesis solution consisting of a synthesis solvent and the polymer. The polymer is thereafter transferred into a solvent of the complex to which said salt is added. The process is characterized in that a solvent of the complex and a non solvent of the polymer are added to the synthesis solution under conditions leading to the formation of an upper phase containing most of the non solvent and a lower phase containing most of the solvent of the complex and most of the polymer, with both phases containing varying amounts of the synthesis solvent, the lower phase is then separated from the upper phase and the salt is added to said lower phase, or the salt is added to the solvent mixture, then the phases are separated. 
     The invention therefore consists in transferring the polymer directly from its synthesis solvent to the solvent of the polymer-salt complex of the electrolyte, without having to precipitate and re-dissolve the polymer. For this purpose, a solvent of the polymer-salt complex and a non-solvent of the polymer are added to the synthesis solution. Two liquid phases appear: an upper phase which mainly consists of the non-solvent and possibly the synthesis solvent, and a lower phase which mainly consists of the solvent of the polymer-salt complex, and which contains nearly all the polymer because of its greater affinity for the latter solvent. After decantation, the lower phase is collected, and the salt, preferably a lithium salt, is added thereto. The salt may also be added with the solvent of the polymer-salt complex during the preceding step. In this manner, it is possible to carry out the &#34;transfer&#34; of the polymer from one solvent to the other. 
     The relative amounts of the three different solvents are selected to give the desired final concentration of polymer and composition of solvents in the lower phase, which are governed by the transfer exchanges between the two phases. 
     The polymers concerned by the invention are all those, including those described above, which may be used as electrolytes in the field of ACEP batteries. The synthesis solvents are usually aromatic hydrocarbons, (benzene, toluene, etc.), aliphatic and cycloaliphatic hydrocarbons (hexane, cyclohexane, etc.), and ethers. Toluene is particularly suitable. The typical concentrations of polymer in these solvents vary with the yield and the conditions of the polymerization reaction and the monomers used. They may vary from 0.01 to 0.5 g of polymer per ml of solution, the more currently used values being from about 0.11 to 0.13 g/ml. 
     In the case where the synthesis solvents consist of aromatic hydrocarbons and ethers, and particularly in the case of toluene, the preferred non-solvents for the transfer process are C 5  to C 15  aliphatic and cycloaliphatic liquid hydrocarbons (above C 15 , they are too viscous), preferably those containing 7 carbon atoms and particularly heptane. 
     In the case where the synthesis solvents are aliphatic and cycloaliphatic hydrocarbons, it is not necessary to add non-solvent for the transfer. 
     The solvents of the polymer-salt complexes of the electrolyte are preferably polar aprotic solvents of the acetonitrile, propylene carbonate, dimethylformamide and tetramethylene sulphone types. Binary mixture of these solvents comprising less than 35 percent by weight of aromatic solvents such as toluene are also suitable, as well as the ternary mixtures containing less than 30 percent by weight of aromatic hydrocarbons such as toluene and less than 5 percent of aliphatic hydrocarbons such as heptane. The acetonitrile/toluene/heptane binary and ternary mixtures are particularly suitable in that they constitute azeotropes which are easier to evaporate from the solutions used for coating the films of electrolytes and positive electrodes. Non-aprotic polar solvents such as alcohols (ethanol, methanol) are also good solvents of the polymer-salt complexes, however, they are not electrochemically compatible with the materials of the positive and negative electrodes of ACEP batteries. 
     The concentrations of polymer in the solvents of the polymer-salt complexes used to prepare the solutions of electrolyte and positive electrode vary typically from 0.01 to 0.5 g of polymer per ml of solution, in order to get acceptable viscosities for coating the solutions. These values depend mainly on the molecular weight of polymer, with typical values ranging from 0.07  g/ml when Mw=300,000 to 0.25 g/ml when Mw=80,000. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     The invention will now be illustrated by means of the annexed drawings given by way of illustration but without limitation and in which: 
     FIG. 1 is a curve illustrating typical polymer concentrations to be used as a function of polymer molecular weight, in order to get polymer solutions with acceptable viscosities with coating methods such as doctor-blade or reverse-roll; and 
     FIG. 2 is a triangular diagram indicating the quantities of acetonitrile and heptane which must be added to those of toluene already present in the synthesis solution (these three quantities being expressed in % with respect to one another), in order to get the desired polymer concentration and acetonitrile content in the lower phase, starting from a given concentration C O  of polymer in the synthesis solution. 
     The triangle coordinates are the following: composition of the solvent mixture before phase separation and transfer: ##EQU1## with: Va=volume of acetonitrile added 
     Vh=volume of heptane added 
     Vt=volume of toluene in the synthesis solution used 
     Vs=volume of synthesis solution used 
     Cs=polymer concentration in the synthesis solution, in g per ml of solution ##EQU2## d=density of the dried polymer. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     The relative amounts of polymer-salt complex solvent and of non-solvent to be added to the polymer synthesis solvent will vary depending on the polymer concentration and solvent composition desired in the lower phase. To simplify the presentation, acetonitrile, heptane and toluene will be used below to represent the three groups of solvents described above, respectively. These examples of solvents should be considered as illustrative and not limiting. 
     The amounts of acetonitrile and heptane to be added to the solution of polymer in toluene should be such that after addition, the lower phase, where the polymer is found in a mixture of solvents containing mostly acetonitrile, has the following properties: 
     1) a viscosity, therefore a polymer concentration, before and after the addition of the lithium salt, which is acceptable for coating the solutions into films. This concentration is governed mostly by the molecular weight of the polymer, and can be deduced from curves such as shown in FIG. 1. The quantities of acetonitrile and heptane to be added will then be dictated by the amount of polymer present or its concentration in the toluene synthesis solution. 
     2) A solvent composition (acetonitrile/toluene/heptane), before and after the addition of the lithium salt, providing a good solubilization of the polymer-salt complex and a rapid drying of the solutions which are used for coating films. Less than 65% acetonitrile does not normally enable to dissolve the polymer-salt complex, and more than 90% sharply reduces the rate of drying. The distribution of the solvents between the lower (mainly acetonitrile) phase and the upper (mainly heptane) phase depends on the solubility of each solvent in the two others, and on the initial volumes of each of them. 
     The quantities of acetonitrile and heptane to be added have been determined experimentally from toluene/acetonitrile/heptane ternary mixtures, with and without the presence of polymer. The volumes of the phases have been measured and their solvent composition analyzed by gas chromatography. It has been observed that the presence of polymer has little or no effect on the distribution of the solvent between the two phases. 
     Table I gives typical values of the quantities of acetonitrile and heptane to be added to obtain various polymer concentrations and acetonitrile contents in the lower phase, starting from 111 ml of a solution of polymer in toluene at a concentration of 0.12 g of polymer per ml of solution and containing therefore 100 ml of toluene (with a density of the polymer of 1.21). If, for example, the concentration to be obtained in the lower phase is 0.128 g/ml, as deduced from FIG. 1 in the case of a molecular weight of 235,000, and the acetonitrile content requested is 80%, Table I indicates that 300 ml heptane and 100 ml acetonitrile should be added. For different starting volumes of solution, simply adjust columns 2 to 6 of Table 1. For different starting concentrations of polymer in toluene C 5 , replace 0.2  by C 5  in column 1, adjust column 2 using the density of the polymer, and multiply column 7 by C S  /0.12. 
     Table I and the triangle may be incorporated in a computer program to facilitate the calculations. 
     The examples which follow illustrate the invention without limiting same. 
     EXAMPLE 1 
     In 30 liters of a synthesis solution of polymer in toluene, at a concentration of 0.12 g of polymer per ml of solution, and with a molecular weight Mw=235,000, 120 liters of heptane are poured slowly. The polymer precipitate is decanted, filtered and dried during several days at room temperature in order to remove heptane absorbed on the polymer, by means of a flow of dry nitrogen, intended to prevent the absorption of humidity and the risks of oxidation of the polymer. 
     EXAMPLE 2 
     0.5 kg of the polymer precipitate of example 1 is slowly poured into 3.5 liters of acetonitrile and the mixture is stirred over rollers. A large block of swelled polymer is obtained which takes about ten days to be dispersed in the solution, which is still barely uniform. When 0.11 kg of lithium salt TFSI (lithium trifluorosulphonimide) is added simultaneously to the polymer, the solution takes about nine days to be dispersed under the same conditions of stirring and is barely uniform. A film of electrolyte which is coated in a dry atmosphere with this latter solution remains still sticky at the surface after 30 minutes of drying at 60° C. 
     EXAMPLE 3 
     0.5 kg of the polymer precipitate from example 2 and 0.11 kg of the lithium salt TFSI are poured into 0.7 liters of toluene, and 2.8 liters of acetonitrile are added. After 4-5 days of stirring under the same conditions as in example 2, a solution is obtained which is highly uniform. A film of electrolyte formed with this solution is not sticky at the surface after 15 minutes of drying at 60° C. The results are even better in the presence of a small amount of heptane (0.2 liters). 
     EXAMPLE 4 
     To carry out a transfer of solvent on the polymer synthesis solution in toluene of example 1 (concentration of 0.12 g/ml and Mw˜235,000), with the aim of obtaining an acetonitrile content in the solvent mixture of the lower phase of 80%, the concentration to be obtained in the lower phase (0.128 g/ml) is first determined by means of FIG. 1, and the quantities of acetonitrile and heptane to be added are determined by means of Table I. 
     To 30 liters of toluene solution, 27 liters of acetonitrile and 81 liters of heptane therefore are added while stirring, the mixture is allowed to rest one hour and the lower phase is collected. Decanting is continued for two days to finish the separation of the upper phase still in emulsion in the lower phase (about 6 liters) and, finally, 25 liters of transferred solution are collected, where the polymer concentration is determined as being 0.128 g/ml and the acetonitrile/toluene/heptane composition 79/13/8, in percent. 
     
                       TABLE I______________________________________Polymerconcentra-   Volume   Volume of Volume oftion Co (g/   Vo       toluene Vt                      heptane Volume ofml) in the   (ml) of  (ml) in the                      added   acetonitriletoluene synthesis solution              Vh (ml)   added Va (ml)______________________________________0.12    111      100       100     1750.12    111      100       200     1100.12    111      100       300      740.12    111      100       350      540.12    111      100       100     2500.12    111      100       200     1750.12    111      100       300     1000.12    111      100       400      460.12    111      100       100     5620.12    111      100       200     3300.12    111      100       300     2070.12    111      100       400      75______________________________________Total    Polymervolume of    concentration               Acetonitrile                          Toluene                                 Heptanesolvent (ml)    C.sub.B (g/ml)               %          %      %in the lower phase______________________________________212      0.059      70         27     3110      0.110      70         21     9 66      0.172      70         18     12 42      0.253      70         18     12287      0.045      80         19     2175      0.072      81         13     6 93      0.128      79         13     8 28      0.340      80         12     8600      0.022      90          9     1330      0.039      90          7     3200      0.063      90          6     4 58      0.193      90          6     4______________________________________