This invention relates to a nonaqueous cell comprising a lithium metallic foil anode and a cathode coating comprising iron disulfide as the active material wherein the coating is applied to at least one surface of a metallic substrate that functions as the cathode current collector. In particular, the cell of the within invention has improved performance on high rate discharge and is achieved, surprisingly, with an anode underbalance. The cell of the within invention has an anode to cathode input that is less than or equal to 1.0. We have discovered, unexpectedly, that the energy density for the cell both volumetrically and gravimetrically can be improved by approximately 20 to 25% while only increasing the volume of the cathode coating solids by approximately 10% through a unique and novel cathode coating formulation used in conjunction with a lithium foil anode.

Patent
   RE41886
Priority
Jun 05 2002
Filed
Feb 16 2007
Issued
Oct 26 2010
Expiry
Jun 05 2022
Assg.orig
Entity
Large
3
166
EXPIRED<2yrs
15. An electrochemical cell comprising a nonaqueous electrolyte, an anode and a cathode assembly, the cathode assembly comprising a metallic cathode current collector having two major surfaces and a cathode coating disposed on at least one of the two major surfaces, the cathode coating comprising iron disulfide, fumed silica, acetylene black and synthetic graphite, and the anode comprising metallic lithium.
1. An electrochemical cell comprising a nonaqueous electrolyte, an anode and a cathode assembly, the electrolyte comprising a solvent, the cathode assembly comprising a metallic cathode current collector having two major surfaces and a cathode coating disposed on at least one of the two major surfaces, the coating comprising iron disulfide, and the anode comprising metallic lithium, wherein the interfacial anode to cathode input ratio is less than or equal to 1.0.
0. 33. An electrochemical cell comprising:
a nonaqueous electrolyte comprising at least one solvent;
a jellyroll electrode assembly having an anode and a cathode assembly wound together;
wherein the cathode assembly comprises a metallic cathode current collector with two major surfaces and a cathode coating comprising iron disulfide disposed on at least one of said two major surfaces; and
wherein the anode comprises metallic lithium; and
wherein an interfacial anode to cathode input ratio for the jellyroll electrode assembly is less than 1.0.
2. The cell of claim 1, wherein the metallic lithium is alloyed with aluminum.
3. The cell of claim 2, wherein the metallic lithium comprises less than 1.0 percent by weight of aluminum.
4. The cell of claim 3, wherein the metallic lithium comprises between 0.1 and 0.9 percent by weight aluminum.
5. The cell of claim 4, wherein the metallic lithium comprises 0.5 percent by weight of aluminum.
6. The cell of claim 1, wherein the cathode coating further comprises a void volume of less than 43 percent.
7. The cell of claim 6, wherein the void volume is from 36 percent to 42 percent.
8. The cell of claim 7, wherein the cathode coating further comprises synthetic graphite.
9. The cell of claim 8, wherein the synthetic graphite is highly crystalline synthetic graphite.
10. The cell of claim 9, wherein the highly crystalline synthetic graphite has a mean particle size of 3.0 to 11.0 microns, a BET surface area of 3.0 to 11.0 m2/gm and an n-dibutyl phthalate oil absorption ratio of 160 to 200 percent.
11. The cell of claim 7, wherein the cathode coating further comprises acetylene black.
12. The cell of claim 7, wherein the cathode coating further comprises a micronized polytetrafluoroethylene powder.
13. The cell of claim 12, wherein the cathode coating further comprises a styrene-ethylene-butylene-styrene block copolymer.
14. The cell of claim 13, wherein the cathode coating further comprises fumed silica.
16. The cell of claim 15, wherein the synthetic graphite and the acetylene black together comprise between 7.0 and 11.0 volume percent of the total solids content of the cathode coating.
17. The cell of claim 16, wherein the synthetic graphite and the acetylene black together comprise between 10.0 and 10.5 volume percent of the total solids content of the cathode coating.
18. The cell of claim 17, wherein the solids volume percent of the synthetic graphite is at least twice the solids volume percent of the acetylene black.
19. The cell of claim 15, wherein the synthetic graphite has a mean particle size of 3.0 to 11.0 microns, a BET surface area of 3.0 to 11.0 m2/gm and an n-dibutyl phthalate oil absorption ratio of 160 to 200 percent.
20. The cell of claim 15, wherein the cathode coating further comprises a micronized polytetrafluoroethylene powder.
21. The cell of claim 20, wherein the cathode coating further comprises a styrene-ethylene-butylene-styrene block copolymer.
22. The cell of claim 15, wherein the metallic lithium is alloyed with aluminum.
23. The cell of claim 18, wherein the cathode coating further comprises micronized polytetrafluoroethylene, and a styrene-ethylene-butylene-styrene block copolymer, and the synthetic graphite comprises highly crystalline synthetic graphite.
24. The cell of claim 23, wherein the cathode components are present in the following solids weight percents: iron disulfide 90.0 to 94.0 percent; acetylene black 1.0 to 3.0 percent; synthetic graphite 3.0 to 6.0 percent; polytetrafluoroethylene 0.2 to 0.6 percent; silica 0.2 to 0.6 percent; SEBS block copolymer 1.5 to 3.0 percent.
0. 25. The cell of claim 2, wherein the cathode coating has a void volume of less than 43 percent.
0. 26. The cell of claim 1, wherein the anode to cathode input ratio is less than or equal to 0.95.
0. 27. The cell of claim 1, wherein the cathode coating further comprises a conductive carbon material.
0. 28. The cell of claim 27, wherein the conductive carbon material is synthetic graphite.
0. 29. The cell of claim 28, wherein the synthetic graphite is highly crystalline synthetic graphite.
0. 30. The cell of claim 27, wherein the conductive carbon material is acetylene black.
0. 31. The cell of claim 1, wherein the cathode coating further comprises a rheological modifier.
0. 32. The cell of claim 31, wherein the rheological modifier comprises a silanol group.
0. 34. The electrochemical cell according to claim 33, wherein the anode to cathode input ratio is less than or equal to 0.95.
0. 35. The electrochemical cell according to claim 33, wherein the metallic lithium is alloyed with aluminum.
0. 36. The electrochemical cell according to claim 35, wherein the anode to cathode input ratio is less than or equal to 0.95.
0. 37. The electrochemical cell according to claim 35, wherein the anode comprises between about 0.1 and 2.0 percent by weight of aluminum.
0. 38. The electrochemical cell according to claim 33, wherein the jellyroll electrode assembly also has an outer wrap comprising polypropylene.
0. 39. The electrochemical cell according to claim 33, wherein the cathode coating has a void volume of less than 43 percent.
0. 40. The electrochemical cell according to claim 33, wherein the cathode coating further comprises a conductive carbon material.
0. 41. The cell of claim 40, wherein the conductive carbon material is highly crystalline synthetic graphite.
0. 42. The cell of claim 40, wherein the conductive carbon material is acetylene black.
0. 43. The cell of claim 33, wherein the cathode coating further comprises a rheological modifier.
0. 44. The cell of claim 43, wherein the rheological modifier comprises a silanol group.
0. 45. The cell of claim 33, wherein the jellyroll electrode assembly has a diameter of at least about 0.525 inches.
0. 46. The cell of claim 33, wherein the jellyroll electrode assembly further comprises an anode tab.
0. 47. The cell of claim 46, wherein the anode tab is bent over the jellyroll electrode assembly.
0. 48. The cell of claim 1, wherein the interfacial anode to cathode input ratio=anode capacity per linear inch/cathode capacity per linear inch; wherein the anode capacity per linear inch=(foil thickness)×(interfacial electrode width)×(density of lithium foil at 20° C.)×(lithium energy density, 3861.7 mAh/g); and wherein the cathode capacity per linear inch=(final cathode coating thickness)×(interfacial electrode width)×(cathode dry mix density)×(final cathode packing percentage)×(dry weight percent FeS2)×(percent purity FeS2)×(FeS2 energy density, 893.58 mAh/g).
0. 49. The cell according to claim 48, wherein the metallic lithium is alloyed with aluminum.
0. 50. The cell according to claim 48, wherein the metallic lithium comprises less than 1.0 percent by weight of aluminum.
0. 51. The cell according to claim 50, wherein the metallic lithium comprises between 0.1 and 2.0 percent by weight of aluminum.
0. 52. The cell according to claim 51, wherein the metallic lithium comprises about 0.5 percent by weight of aluminum.
0. 53. The cell according to claim 48, wherein the cathode coating further comprises a void volume of less than 43 percent.
0. 54. The cell according to claim 56, wherein the void volume is from 36 percent to 42 percent.
0. 55. The cell according to claim 48, wherein the cathode coating further comprises synthetic graphite.
0. 56. The cell according to claim 55, wherein the synthetic graphite has a mean particle size of 3.0 to 11.0 Pm, a BET surface area of 3.0 to 11.0 m2/g, and a DBP of 160 to 200 percent.
0. 57. The cell according to claim 48, wherein the cathode coating further comprises acetylene black.
0. 58. The cell according to claim 48, wherein the cathode coating further comprises a micronized polytetrafluoroethylene powder.
0. 59. The cell according to claim 48, wherein the cathode coating further comprises a styrene-ethylene-butylenestyrene block copolymer.
0. 60. The cell according to claim 48, wherein the cathode coating further comprises fumed silica.
0. 61. The cell according to claim 48, wherein the cathode coating further comprises a total of between 7.0 and 11.0 percent synthetic graphite and acetylene black, based on the total solids content of the cathode coating.
0. 62. The cell according to claim 48, wherein the synthetic graphite and the acetylene black together comprise between 10.0 and 10.5 volume percent of the total solids content of the cathode coating.
0. 63. The cell according to claim 48, wherein the solids volume percent of the synthetic graphite is at least twice the solids volume percent of the acetylene black.
0. 64. The cell according to claim 48, wherein the electrolyte comprises an organic solvent.
0. 65. The cell according to claim 48, wherein the cathode assembly and the anode are wound together into a jellyroll electrode assembly.


Cathode Capacity Per Linear Inch:
(final cathode coating thickness)×(interfacial electrode width)×1 inch×(cathode dry mix density)×(final cathode packing percentage)×(dry weight percent FeS2)×(percent purity FeS2)×(FeS2 energy density, 893.58 mAh/gm)
Anode/cathode input ratio-anode capacity per linear inch/cathode capacity per linear inch

“Interfacial electrode width” as used herein is the linear dimension that shares an interfacial area between the cathode and the anode. An example is illustrated in FIG. 1, where the dimension labeled “A” is the interfacial electrode width. “Final cathode coating thickness” refers to the coating thickness after any calendering operation or other densification processing of the cathode. “Final cathode packing percentage” refers to the solid volume percentage after any calendering operation or other densification processing and is equivalent to 100 percent less the void volume percentage after any calendering operation or other densification processing of the cathode. The “cathode dry mix density” refers to the additive density of the solid components of the cathode coating.

A preferred polymer binder for the cathode coating of the cell of the within invention is a styrene-ethylene/butylene-styrene (SEBS) block copolymer. One such suitable block copolymer is available commercially from Kraton Polymers of Houston, Tex. as Kraton G1651. The preferred solvent for use with such a binder is stabilized 1,1,2-trichloroethylene. One of skill in the art will appreciate that other combinations of binders and/or solvents may be utilized in the cathode coating of the cell of the within invention without departing from the scope of the within invention

An electrochemical cell comprising lithium as the active anode material and pyrite as the active cathode material is constructed as follows. A continuous strip of lithium metal foil 0.006 inches thick by 1.535 inches wide and alloyed at 0.5 weight percent with aluminum is provided. An aluminum cathode current collector continuous strip 0.001 inches thick by 1.72 inches wide is provided. The aluminum cathode collector strip is full hard standard alloy 1145-H19 aluminum and both surfaces are flame cleansed to remove oils and improve adhesion of the coating to the substrate surface.

A cathode coating slurry is prepared using the following solids:

Material Weight percent (dry) cm3/100 gms
FeS2 92.0 19.087
Acetylene black 1.4 0.733
Highly crystalline 4.0 1.777
synthetic graphite
Formed silica 0.3 0.136
Micronized PTFE 0.3 0.136
Kraton 2.0 2.198
24.067 cm3/100 gms
4.155 gm/cm3

Cathode capacity per linear inch:
(0.0063 in.)(1.535 in.)(1.0 in.)(16.387 cm3/in3) (4.1555 gm/cm3)(0.64 solids packing) (0.92) (0.95)(893.58 mAh/gm )=329 mAh/linear inch
Anode capacity per linear inch:
(0.006 in.)(1.535 in.)(1.0 in.)(16.387 cm3/in3)(0.534 gm/cm3)(3861.7 mAh/gm)=311 mAh/linear inch
The resulting anode to cathode input ratio is 311/329=0.95.

The anode, cathode and a suitable separator are wound together from continuous webs into an electrode assembly with an overwrap on the exterior of the jelly roll and disposed within a can or other suitable container. A plastic insulating disc is punched and placed into each can initially. Automatic winders initiate the jellyroll with separator, followed by the cathode. The anode is introduced into the winder after the cathode and the jellyroll is formed to predetermined electrode lengths based on the location of the anode tab. The winder feed stock is separated from the web and an overwrap film is introduced into the winder at the trail end of the jellyroll and wound over the jellyroll until a predetermined jellyroll diameter is obtained. The wrap is cut and heat sealed, the cathode collector is crimped and the jellyroll is inserted into the container. The can is swaged to reduce its diameter prior to electrolyte filling.

Conventional cell assembly and closing methods are utilized to complete the final cell, followed by a predischarge regimen. The anode tab is a 0.002 inch thick nickel plated steel foil tab that is pressure bonded to the lithium foil web at predetermined intervals corresponding to the predetermined prewind anode length of 12.00 inches and is bent over the completed jellyroll prior to insertion of the jellyroll into the can. The separator is a 25 micron thick polypropylene material available from Celgard Corporation as Celgard 2400. The can is nickel plated steel with an outer diameter of 0.548 inches and the jellyroll finished diameter is 0.525 inches. The outer wrap is a polypropylene film. The electrolyte is 1.6 grams of 63.05 weight percent 1,3 dioxolane, 27.63 weight percent 1,2 dimethoxyethane, 0.18 weight percent 3,5 dimethylisoxazole, and 9.14 weight percent lithium iodide.

Marple, Jack W.

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