Global Graphene Group, Inc.

Nanotek Instruments, Inc.

Baofei Pan

Bor Z Jang

Hui He

Aruna Zhamu

Yu-Sheng Su

A method of producing a powder mass for a lithium battery, the method comprising: (a) providing a solution containing a sulfonated elastomer dissolved in a solvent or a precursor in a liquid form or dissolved in a solvent; (b) dispersing a plurality of particles of a cathode active material in the solution to form a slurry; and (c) dispensing the slurry and removing the solvent and/or polymerizing/curing the precursor to form the powder mass, wherein the powder mass comprises multiple particulates and at least a particulate comprises one or a plurality of particles of a cathode active material being encapsulated by a thin layer of sulfonated elastomer having a thickness from 1 nm to 10 &#x3bc;m, a fully recoverable tensile strain from 2% to 800%, and a lithium ion conductivity from 10S/cm to 5&#xd7;10S/cm at room temperature.

Method of producing protected particles of cathode active materials for lithium batteries

A method of producing a powder mass for a lithium battery, comprising: (a) mixing an inorganic filler and an elastomer or its precursor in a liquid medium or solvent to form a suspension; (b) dispersing a plurality of particles of a cathode active material in the suspension to form a slurry; and (c) dispensing the slurry and removing the solvent and/or polymerizing or curing the precursor to form the powder mass, wherein at least a particulate comprises one or a plurality of cathode active material particles being encapsulated by a layer of inorganic filler-reinforced elastomer having a thickness from 1 nm to 10 &#x3bc;m, a fully recoverable tensile strain from 2% to 500%, and a lithium ion conductivity from 10S/cm to 5&#xd7;10S/cm and the inorganic filler has a lithium intercalation potential from 1.1 V to 4.5 V versus Li/Li.

Method of producing electrochemically stable elastomer-encapsulated particles of cathode active materials for lithium batteries

Provided is a surface-stabilized anode active material particulate (for use in a lithium battery), comprising: (a) one or a plurality of prelithiated or un-prelithiated anode active material particles (with or without a coating of carbon, graphene, or ion-conducting polymer); (b) a protecting polymer layer that wraps around, embraces or encapsulates the one or plurality of anode active material particles, wherein the protecting polymer layer has a thickness from 0.5 nm to 5 &#x3bc;m, and a lithium ion conductivity from 10S/cm to 5&#xd7;10S/cm at room temperature and the protecting polymer layer contains a polymer selected from poly(ethylene oxide) (PEO), polypropylene oxide (PPO), poly(acrylonitrile) (PAN), poly(methyl methacrylate) (PMMA), poly(vinylidene fluoride) (PVdF), poly bis-methoxy ethoxyethoxide-phosphazene, polyvinyl chloride, poly(vinylidene chloride), polydimethylsiloxane, poly(vinylidene fluoride)-hexafluoropropylene (PVDF-HFP), polyethylene glycol (PEG), a PEG derivative, polyethylene glycol methyl ether, polyethylene glycol dimethyl ether, a sulfonated polymer, or a combination thereof.

Surface-stabilized anode active material particulates for lithium batteries and production method

Provided is a lithium battery cathode electrode comprising multiple particulates of a cathode active material, wherein at least a particulate is composed of one or a plurality of particles of a cathode active material being encapsulated by a thin layer of inorganic filler-reinforced elastomer having from 0.01% to 50% by weight of an inorganic filler dispersed in an elastomeric matrix material based on the total weight of the inorganic filler-reinforced elastomer, wherein the encapsulating thin layer of inorganic filler-reinforced elastomer has a thickness from 1 nm to 10 &#x3bc;m, a fully recoverable tensile strain from 2% to 500%, and a lithium ion conductivity from 10S/cm to 5&#xd7;10S/cm and the inorganic filler has a lithium intercalation potential from 1.1 V to 4.5 V (preferably 1.2-2.5 V) versus Li/Li.

Electrochemically stable elastomer-encapsulated particles of cathode active materials for lithium batteries

Provided is a lithium battery anode electrode comprising multiple particulates of an anode active material, wherein at least a particulate is composed of one or a plurality of particles of an anode active material being encapsulated by a thin layer of inorganic filler-reinforced elastomer having from 0.01% to 50% by weight of an inorganic filler dispersed in an elastomeric matrix material based on the total weight of the inorganic filler-reinforced elastomer, wherein the encapsulating thin layer of inorganic filler-reinforced elastomer has a thickness from 1 nm to 10 &#x3bc;m, a fully recoverable tensile strain from 2% to 500%, and a lithium ion conductivity from 10to S/cm to 5&#xd7;10S/cm and the inorganic filler has a lithium intercalation potential from 1.1 V to 4.5 V (preferably 1.2-2.5 V) versus Li/Li. The anode active material is preferably selected from Si, Ge, Sn, SnO, SiO, CoO, MnO, etc.

Electrochemically stable elastomer-encapsulated particles of anode active materials for lithium batteries

Provided is cathode active material layer for a lithium battery. The cathode active material layer comprises multiple cathode active material particles and an optional conductive additive that are bonded together by a binder comprising a high-elasticity polymer having a recoverable tensile strain from 5% to 700% (preferably from 10% to 100%) when measured without an additive or reinforcement in said polymer and a lithium ion conductivity no less than 10S/cm (preferably and typically from 1.0&#xd7;10S/cm to 5&#xd7;10S/cm) at room temperature.

Lithium battery cathode and method of manufacturing

A rechargeable lithium cell comprising a cathode, an anode, a non-flammable electrolyte, wherein the electrolyte contains a lithium salt dissolved in a liquid solvent having a lithium salt concentration from 0.01 M to 10 M so that the electrolyte exhibits a vapor pressure less than 0.01 kPa when measured at 20&#xb0; C., a vapor pressure less than 60% of the vapor pressure of the liquid solvent alone, a flash point at least 20 degrees Celsius higher than a flash point of the liquid solvent alone, a flash point higher than 200&#xb0; C., or no flash point, wherein the liquid solvent contains a cooking oil selected from palm oil, palm olein, coconut oil, corn oil, soybean oil, cottonseed oil, peanut oil, sunflower oil, canola oil, rice bran oil, olive oil, sesame oil, safflower oil, avocado oil, flaxseed oil, grapeseed oil, walnut oil, almond oil, lard, or a combination thereof.

Lithium secondary battery containing non-flammable electrolyte and manufacturing method

Provided is a lithium battery cathode electrode comprising multiple particulates of a cathode active material, wherein at least a particulate comprises one or a plurality of particles of a cathode active material being encapsulated by a thin layer of a sulfonated elastomer, wherein the encapsulating thin layer of sulfonated elastomer has a thickness from 1 nm to 10 &#x3bc;m, a fully recoverable tensile strain from 2% to 800%, and a lithium ion conductivity from 10S/cm to 5&#xd7;10S/cm. The encapsulating layer may further contain an electron-conducting additive and/or a lithium ion-conducting additive dispersed in the sulfonated elastomer.

Protected particles of cathode active materials for lithium batteries

Provided is an anode particulate, having a dimension from 10 nm to 300 &#x3bc;m, for use in an alkali metal battery, the particulate comprising (i) an anode active material capable of reversibly absorbing/desorbing lithium or sodium ions, (ii) an electron-conducting material, and (iii) a lithium or sodium salt with an optional polymer or its monomer, but without a liquid solvent, for an electrolyte, wherein the electron-conducting material forms a 3D network of electron-conducting pathways in electronic contact with the anode active material and the lithium or sodium salt is in physical contact with the anode active material (so that the salt, when later impregnated with a liquid solvent, becomes an electrolyte forming a 3D network of lithium or sodium ion-conducting channels in ionic contact with the anode active material). The particulate can be of any shape, but preferably spherical or ellipsoidal in shape. Also provided is a cathode particulate.

Anode particulates or cathode particulates and alkali metal batteries

Provided is lithium secondary battery comprising a cathode, an anode, and an electrolyte or separator-electrolyte assembly disposed between the cathode and the anode, wherein the anode comprises: (a) a foil or coating of lithium or lithium alloy; and (b) a thin layer of a high-elasticity polymer disposed between the foil/coating and the electrolyte (or separator-electrolyte assembly), having a recoverable tensile strain no less than 2%, a lithium ion conductivity no less than 10S/cm at room temperature, and a thickness from 1 nm to 10 &#x3bc;m, wherein the high-elasticity polymer contains a cross-linked network of polymer chains having an ether linkage, nitrile-derived linkage, benzo peroxide-derived linkage, ethylene oxide linkage, propylene oxide linkage, vinyl alcohol linkage, cyano-resin linkage, triacrylate monomer-derived linkage, tetraacrylate monomer-derived linkage, or a combination thereof in the cross-linked network of polymer chains.

Lithium anode-protecting polymer layer for a lithium metal secondary battery and manufacturing method

Provided is an anode active material layer for a lithium battery. The anode active material layer comprises multiple anode active material particles and an optional conductive additive that are bonded together by a binder comprising a high-elasticity polymer having a recoverable or elastic tensile strain no less than 10% when measured without an additive or reinforcement in the polymer and a lithium ion conductivity no less than 10S/cm at room temperature. The anode active material preferably has a specific lithium storage capacity greater than 372 mAh/g (e.g. Si, Ge, Sn, SnO, CoO, etc.).

Polymer binder for lithium battery and method of manufacturing

A method of producing a powder mass for a lithium battery, comprising: (a) mixing an inorganic filler and an elastomer or its precursor in a liquid medium or solvent to form a suspension; (b) dispersing a plurality of particles of an anode active material in the suspension to form a slurry; and (c) dispensing the slurry and removing the solvent and/or polymerizing or curing the precursor to form the powder mass, wherein at least a particulate is composed of one or a plurality of anode particles being encapsulated by a layer of inorganic filler-reinforced elastomer having a thickness from 1 nm to 10 &#x3bc;m, a fully recoverable tensile strain from 2% to 500%, and a lithium ion conductivity from 10S/cm to 5&#xd7;10S/cm and the inorganic filler has a lithium intercalation potential from 1.1 V to 4.5 V versus Li/Li.

Method of producing electrochemically stable elastomer-encapsulated particles of anode active materials for lithium batteries

Provided is method of producing anode or cathode particulates for an alkali metal battery. The method comprises: (a) preparing a slurry containing particles of an anode or cathode active material, an electron-conducting material, and an electrolyte containing a lithium salt or sodium salt and an optional polymer dissolved in a liquid solvent; and (b) conducting a particulate-forming means to convert the slurry into multiple anode or cathode particulates, wherein an anode or a cathode particulate is composed of (i) particles of the active material, (ii) the electron-conducting material, and (iii) an electrolyte, wherein the electron-conducting material forms a 3D network of electron-conducting pathways and the electrolyte forms a 3D network of lithium ion- or sodium ion-conducting channels and wherein the anode particulate or cathode particulate has a dimension from 10 nm to 100 &#x3bc;m and an electrical conductivity from about 10S/cm to about 300 S/cm.

Method of producing anode or cathode particulates for alkali metal batteries

Provided is a lithium secondary battery, comprising a cathode, an anode, and a porous separator or electrolyte, wherein the anode comprises: (a) an anode active layer containing a layer of lithium or lithium alloy, in a form of a foil, coating, or multiple particles aggregated together, as an anode active material; (b) a first anode-protecting layer having a thickness from 1 nm to 100 &#x3bc;m, a specific surface area greater than 50 m/g and comprising a thin layer of electron-conducting material selected from graphene sheets, carbon nanotubes, carbon nanofibers, carbon or graphite fibers, expanded graphite flakes, metal nanowires, conductive polymer fibers, or a combination thereof, and (c) a second anode-protecting layer having a thickness from 1 nm to 100 &#x3bc;m and comprising an elastomer having a fully recoverable tensile elastic strain from 2% to 1,000% and a lithium ion conductivity from 10S/cm to 5&#xd7;10S/cm.

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Dayton, OH, United States of America

Baofei Pan