Method of making lithium-ion cell having deactivated carbon anodes

Claim 2

In the method of making a secondary, lithium-ion cell including the principle step of positioning an anode and a cathode opposite each other with a non-aqueous, lithium-ion conducting electrolyte therebetween wherein said anode comprises a reversible-lithium-intercalateable carbon and said cathode comprises a reversible-lithium-intercalateable material, the improvement comprising, prior to said positioning, heating said carbon in the presence of oxygen for a time and at a temperature sufficient to selectively oxidize, gasify and remove from said carbon at least those highly reactive carbon atoms therein that would otherwise decompose said electrolyte and/or entrap lithium in said cell.

Claim 3

In the method of making a secondary, anode-loaded, lithium-ion cell including the principle step of positioning an anode and a cathode opposite each other with a non-aqueous, lithium-ion conducting electrolyte therebetween wherein said anode comprises carbon intercalated with reversible lithium and said cathode comprises a lithium-retentive material which intercalates said reversible lithium during the charging of said cell, the improvement comprising prior to said positioning, heating said carbon in the presence of oxygen for a time and at a temperature sufficient to selectively oxidize, gasify and remove from said carbon at least those highly reactive carbon atoms therein that would otherwise react with, and non-usefully chemically consume, lithium and render it electrochemically non-reversible in said cell.

Claim 4

In the method of making a secondary, anode-loaded, lithium-ion cell including the principle step of positioning an anode and a cathode opposite each other with a non-aqueous, lithium-ion conducting electrolyte therebetween wherein said anode comprises carbon intercalated with reversible lithium and said cathode comprises a lithium-retentive material which intercalates said reversible lithium during the charging of said cell, the improvement comprising prior to said positioning, heating said carbon in the presence of oxygen for a time and at a temperature sufficient to selectively oxidize, gasify and remove from said carbon at least those highly reactive carbon atoms therein that would otherwise react with, and non-usefully chemically consume, lithium and render it electrochemically non-reversible in said cell.

Claim 5

In the method of making a secondary, cathode-loaded, lithium-ion cell including the principle step of positioning an anode and a cathode opposite each other with a non-aqueous, lithium-ion-conducting electrolyte therebetween, wherein said anode comprises lithium-intercalatable carbon and said cathode comprises a lithium-retentive material substantially saturated with a quantity of electrochemically reversible lithium species, the improvement comprising, before said positioning, heating said carbon in an oxygen-containing atmosphere for a time and at a temperature sufficient to selectively oxidize, gasify and remove from said carbon at least those highly reactive carbon atoms therein that would otherwise react with and decompose said electrolyte during the initial charging of said cell and leave said carbon with sufficient residual lithium capacity to reversibly intercalate said quantity of reversible lithium species.

Claim 6

In the method of making a secondary, cathode-loaded, lithium-ion cell including the principle step of positioning an anode and a cathode opposite each other with a non-aqueous, lithium-ion-conducting electrolyte therebetween, wherein said anode comprises lithium-intercalatable carbon and said cathode comprises a lithium-retentive material substantially saturated with a quantity of electrochemically reversible lithium species, the improvement comprising, before said positioning, heating said carbon in an oxygen-containing atmosphere for a time and at a temperature sufficient to selectively oxidize, gasify and remove from said carbon at least those highly reactive carbon atoms therein that would otherwise react with and decompose said electrolyte during the initial charging of said cell and leave said carbon with sufficient residual lithium capacity to reversibly intercalate said quantity of reversible lithium species.

Claim 7

The method according to claim 3 wherein said atmosphere comprises air.

Claim 8

The method according to claim 4 wherein said temperature is at least about 400° C. and less than about 800° C.

Claim 9

The method according to claim 4 wherein said time varies inversely with respect to said temperature between about 0.1 hours and about 10 hours.

Claim 10

Method according to claim 4 wherein said carbon is heated for about four hours at about 650° C.

Claim 11

A substantially stoichiometrically balanced lithium-polymer cell comprising a polymeric electrolyte interposed between a lithium-intercalateable carbon anode and a lithium-intercalateable cathode wherein said carbon (a) has a lithium intercalateability which substantially matches the lithium intercalatebility of said cathode, (b) is substantially unreactive with said electrolyte and lithium species during the first electrochemical cycle of said cell, and (c) was deactivated by selectively oxidatively removing highly reactive carbon atoms from said carbon prior to assembly of said cell.

Claim 12

A substantially stoichiometrically balanced lithium-polymer cell comprising a polymeric electrolyte interposed between a lithium-intercalateable carbon anode and a lithium-intercalateable cathode wherein said carbon (a) has a lithium intercalateability which substantially matches the lithium intercalatebility of said cathode, (b) is substantially unreactive with said electrolyte and lithium species during the first electrochemical cycle of said cell, and (c) was deactivated by selectively oxidatively removing highly reactive carbon atoms from said carbon prior to assembly of said cell.

Claim 13

The cell according to claim 8 wherein said cathode material comprises a transition metal chalcogenide.

Claim 14

The cell according to claim 9 wherein said transition metal chalcogenide is an oxide.

Claim 15

The cell according to claim 10 wherein said transition metal comprises manganese.

Claim 16

The cell according to claim 8 wherein said electrolyte is substantially immobilized in a polymer matrix.

Claim 17

The cell according to claim 11 wherein said cathode material comprises a transition metal oxide.

Claim 18

The cell according to claim 13 wherein said transition metal is manganese.

Claim 19

The cell according to claim 14 wherein said cathode material comprises lithium manganese oxide.