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.
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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.
3. The cell of
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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
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.
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