US5919587A
Expired / Lapsed
US
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Composite cathodes, electrochemical cells comprising novel composite cathodes, and processes for fabricating same
Assignee: Sion Power Corp
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Filing: 1997-05-21
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Granted: 1999-07-06
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Expires: 2017-05-21
Abstract
Abstract The present invention pertains to composite cathodes suitable for use in an electrochemical cell, said cathodes comprising: (a) an electroactive sulfur-containing cathode material, wherein said electroactive sulfur-containing cathode material, in its oxidized state, comprises a polysulfide moiety of the formula --S m --, wherein m is an integer equal to or greater than 3; and, (b) an electroactive transition metal chalcogenide composition, which encapsulates said electroactive sulfur-containing cathode material, and which retards the transport of anionic reduction products of said electroactive sulfur-containing cathode material, said electroactive transition metal chalcogenide composition comprising an electroactive transition metal chalcogenide having the formula M j Y k (OR) l wherein: M is a transition metal; Y is the same or different at each occurrence and is oxygen, sulfur, or selenium; R is an organic group and is the same or different at each occurrence; j is an integer ranging from 1 to 12; k is a number ranging from 0 to 72; and l is a number ranging from 0 to 72; with the proviso that k and l cannot both be 0. The present invention also pertains to methods of making such composite cathodes, cells comprising such composite cathodes, and methods of making such cells.
Inventors
- 👤 Shyama P. Mukherjee
- 👤 Terje A. Skotheim
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 21:32
CPC Classifications
H; H01; H01M; H01M4/00; H01M4/02; H01M4/36; H01M4/60; H01B; H01B1/00; H01B1/06; H01B1/12; H01M10/00; H01M10/05; H01M10/052; H01M10/056; H01M10/0564; H01M10/0566; H01M10/0569; H01M4/04; H01M4/0402; H01M4/0404; H01M4/13; H01M4/131; H01M4/136; H01M4/139; H01M4/1397; H01M4/362; H01M4/364; H01M4/366; H01M4/48; H01M4/58; H01M4/581; H01M4/5815; H01M4/602; H01M4/62; H01M4/621; H01M4/622; H01M10/0525; H01M10/054; H01M10/058; H01M10/0587; H01M2004/021; H01M2004/026; H01M2004/028; H01M10/42; H01M2010/4292; H01M2300/00; H01M2300/0017; H01M2300/0025; H01M2300/0065; H01M2300/0082; H01M2300/0085; H01M4/137; H01M4/38; H01M4/40; H01M4/405; H01M4/485; H01M4/5825; H01M4/583; H01M4/587; H01M6/00; H01M6/14; H01M6/16; H01M6/162; H01M6/166; H01M6/40; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y02P; Y02P70/00; Y02P70/50; Y10; Y10S; Y10S977/00; Y10S977/902; Y10S977/932; Y10S977/948
Claims Analysis
Total Claims: 52
Claim 1
Independent Claim
171 words
A composite cathode for use in an electrochemical cell, said cathode comprising: (a) an electroactive sulfur-containing cathode material, wherein said electroactive sulfur-containing cathode material, in its oxidized state, comprises a polysulfide moiety of the formula --S m --, wherein m is an integer equal to or greater than 3; and, (b) an electroactive transition metal chalcogenide composition, which encapsulates said electroactive sulfur-containing cathode material, and which retards the transport of anionic reduction products of said electroactive sulfur-containing cathode material, said electroactive transition metal chalcogenide composition comprising an electroactive transition metal chalcogenide having the formula: M.sub.j Y.sub.k (OR).sub.l wherein: M is a transition metal; Y is the same or different at each occurrence and is oxygen, sulfur, or selenium; R is an organic group and is the same or different at each occurrence; j is an integer ranging from 1 to 12; k is a number ranging from 0 to 72; and l is a number ranging from 0 to 72; with the proviso that k and l cannot both be 0.
Claim 2
Dependent Claim
171 words
A composite cathode for use in an electrochemical cell, said cathode comprising: (a) an electroactive sulfur-containing cathode material, wherein said electroactive sulfur-containing cathode material, in its oxidized state, comprises a polysulfide moiety of the formula --S m --, wherein m is an integer equal to or greater than 3; and, (b) an electroactive transition metal chalcogenide composition, which encapsulates said electroactive sulfur-containing cathode material, and which retards the transport of anionic reduction products of said electroactive sulfur-containing cathode material, said electroactive transition metal chalcogenide composition comprising an electroactive transition metal chalcogenide having the formula: M.sub.j Y.sub.k (OR).sub.l wherein: M is a transition metal; Y is the same or different at each occurrence and is oxygen, sulfur, or selenium; R is an organic group and is the same or different at each occurrence; j is an integer ranging from 1 to 12; k is a number ranging from 0 to 72; and l is a number ranging from 0 to 72; with the proviso that k and l cannot both be 0.
Claim 3
Dependent Claim
36 words
The composite cathode according to claim 1, wherein: j is an integer ranging from 1 to 6; k is a number ranging from 0 to 13; and, l is a number ranging from 0 to 18.
Claim 4
Dependent Claim
46 words
The composite cathode according to claim 1, wherein said transition metal of said electroactive transition metal chalcogenide is selected from the group consisting of: Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Y, Zr, Nb, Mo, Ru, Rh, Pd, Hf, Ta, W, Re, Os, and Ir.
Claim 5
Dependent Claim
59 words
The composite cathode according to claim 3, wherein said electroactive transition metal chalcogenide is selected from the group consisting of: TiS 2 , Cr 2 S 3 , MoS 2 , MoSe 2 , MnS 2 , NbS 2 , VS 2 , V 2 S 5 , WS 2 , and V 2 O 3 S 3 .
Claim 6
Dependent Claim
11 words
The composite cathode according to claim 3, wherein Y is oxygen.
Claim 7
Dependent Claim
63 words
The composite cathode according to claim 4, wherein said electroactive transition metal chalcogenide is selected from the group consisting of: MoO 2 , MnO 2 , NbO 5 , V 2 O 5 , WO 3 , MoO 3 , Ta 2 O 5 , V 2 O 4 .5 (OCH(CH 3 ) 2 ) 0 .5, and V 2 O 4 .5.
Claim 8
Dependent Claim
38 words
The composite cathode according to claim 1, wherein l is greater than 0, and said organic group is selected from the group consisting of: alkyl, aryl, arylalkyl, alkanone, alkanol, and alkoxy groups, each containing 1 to 18 carbons.
Claim 9
Dependent Claim
53 words
The composite cathode according to claim 1, wherein l is greater than 0, and said organic group is selected from the group consisting of: methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tertiary butyl, pentyl, isopentyl, hexyl, octyl, ethylhexyl, isooctyl, dodecyl, cyclohexyl, decahydronaphthyl, phenyl, methylphenyl, ethylphenyl, hexylphenyl, dodecylphenyl, isopropylphenyl, benzyl, phenylethyl, naphthyl, acetyl, and acetoacetylonate.
Claim 10
Dependent Claim
71 words
The composite cathode according to claim 1, wherein: M is selected from the group consisting of V, Nb, Cr, Mo, Mn, W, and Ta; Y is oxygen; R is selected from the group consisting of: ethyl, isopropyl, butyl, acetyl, and acetylacetonate; j is an integer ranging from 1 to 6; k is a number ranging from 1 to less than 14; and, l is equal to or less than about 1.5.
Claim 11
Dependent Claim
19 words
The composite cathode according to claim 1, wherein said transition metal of said electroactive transition metal chalcogenide is V.
Claim 12
Dependent Claim
11 words
The composite cathode according to claim 10, wherein Y is oxygen.
Claim 13
Dependent Claim
17 words
The composite cathode according to claim 11, wherein said electroactive transition metal chalcogenide is a vanadium oxide.
Claim 14
Dependent Claim
28 words
The composite cathode according to claim 11, wherein said electroactive transition metal chalcogenide composition comprises an aerogel comprising a vanadium oxide or a xerogel comprising a vanadium oxide.
Claim 15
Dependent Claim
19 words
The composite cathode according to claim 12, wherein said electroactive transition metal chalcogenide is V 2 O 5 .
Claim 16
Dependent Claim
17 words
The composite cathode according to claim 10, wherein said electroactive transition metal chalcogenide is a vanadium alkoxide.
Claim 17
Dependent Claim
18 words
The composite cathode according to claim 10, wherein said electroactive transition metal chalcogenide is a vanadium oxide isopropoxide.
Claim 18
Dependent Claim
29 words
The composite cathode according to claim 1, wherein said electroactive transition metal chalcogenide is present in said composite cathode in the amount of from 2 to 70 weight %.
Claim 19
Dependent Claim
29 words
The composite cathode according to claim 1, wherein said electroactive transition metal chalcogenide is present in said composite cathode in the amount of from 5 to 50 weight %.
Claim 20
Dependent Claim
29 words
The composite cathode according to claim 1, wherein said electroactive transition metal chalcogenide is present in said composite cathode in the amount of from 5 to 40 weight %.
Claim 21
Dependent Claim
26 words
The composite cathode according to claim 1, wherein said electroactive transition metal chalcogenide composition comprises an aerogel or a xerogel comprising an electroactive transition metal chalcogenide.
Claim 22
Dependent Claim
35 words
The composite cathode according to claim 1, wherein said electroactive transition metal chalcogenide composition encapsulates said electroactive sulfur-containing cathode material by impregnation of said electroactive sulfur-containing cathode material into said electroactive transition metal chalcogenide composition.
Claim 23
Dependent Claim
30 words
The composite cathode according to claim 1, wherein said electroactive transition metal chalcogenide composition is present as an interface layer on the outer surface of said electroactive sulfur-containing cathode material.
Claim 24
Dependent Claim
49 words
The composite cathode according to claim 1, wherein said composite cathode comprises: (a) a first coating on an electrically conductive substrate, said first coating comprising said electroactive sulfur-containing cathode material; and, (b) a second coating over said first coating, said second coating comprising said electroactive transition metal chalcogenide composition.
Claim 25
Dependent Claim
23 words
The composite cathode according to claim 23, wherein said second coating comprises greater than 2.5 g/m 2 of said electroactive transition metal chalcogenide.
Claim 26
Dependent Claim
13 words
The composite cathode of claim 1, wherein said sulfur-containing material comprises elemental sulfur.
Claim 27
Dependent Claim
15 words
The composite cathode of claim 1, wherein said sulfur-containing material comprises a carbon-sulfur polymer material.
Claim 28
Dependent Claim
35 words
The composite cathode of claim 26, wherein said sulfur-containing material is a carbon-sulfur polymer material, wherein m of the polysulfide moiety of said carbon-sulfur polymer material is an integer equal to or greater than 6.
Claim 29
Dependent Claim
19 words
The composite cathode of claim 26, wherein the polymer backbone chain of said carbon-sulfur polymer material comprises conjugated segments.
Claim 30
Dependent Claim
39 words
The composite cathode of claim 26, wherein said polysulfide moiety, --S m --, is covalently bonded by one or both of its terminal sulfur atoms on a side group to the polymer backbone chain of said carbon-sulfur polymer material.
Claim 31
Dependent Claim
35 words
The composite cathode of claim 26, wherein said polysulfide moiety, --S m --, is incorporated into the polymer backbone chain of said carbon-sulfur polymer material by covalent bonding of said polysulfide moiety's terminal sulfur atoms.
Claim 32
Dependent Claim
19 words
The composite cathode of claim 26, wherein said carbon-sulfur polymer material comprises greater than 75 weight percent of sulfur.
Claim 33
Dependent Claim
30 words
The composite cathode according to claim 1, wherein said composite cathode further comprises one or more of the materials selected from the group consisting of: binders, electrolytes, and conductive additives.
Claim 34
Dependent Claim
43 words
The composite cathode according to claim 1, wherein said composite cathode further comprises one or more binders selected from the group consisting of: polytetrafluoroethylene, polyvinylidene fluorides, ethylene propylene diene rubbers, polyethylene oxides, UV curable acrylates, UV curable methacrylates, and UV curable divinyl ethers.
Claim 35
Dependent Claim
34 words
The composite cathode according to claim 1, wherein said composite cathode further comprises one or more conductive additives selected from the group consisting of: conductive carbons, graphites, metal flakes, metal powders, and conductive polymers.
Claim 36
Dependent Claim
125 words
A method for preparing a composite cathode according to claim 1, said method comprising the steps of: (a) dissolving or dispersing said electroactive transition metal chalcogenide in a liquid medium; (b) adding to the composition resulting from step (a) said electroactive sulfur-containing cathode material; (c) mixing the composition resulting from step (b) to dissolve or disperse said electroactive sulfur-containing cathode material; (d) casting the composition resulting from step (c) onto a suitable substrate or placing the composition resulting from step (c) into a mold; (e) removing some or all of the liquid from the composition resulting from step (d) to provide a solid composite cathode structure; and, (f) optionally heating the composite cathode structure of step (e) to a temperature of 100° C. or greater.
Claim 37
Dependent Claim
141 words
A method for preparing a composite cathode according to claim 1, said method comprising the steps of: (a) dissolving or dispersing said electroactive transition metal chalcogenide in a liquid medium; (b) adding to the composition resulting from step (a) said electroactive sulfur-containing cathode material; (c) mixing the composition resulting from step (b) to dissolve or disperse said electroactive sulfur-containing cathode material; (d) contacting the composition resulting from step (c) with a gelling agent, thereby forming a sol-gel; (e) casting the composition resulting from step (d) onto a suitable substrate or placing the composition resulting from step (d) into a mold; (f) removing some or all of the liquid from the composition resulting from step (e) to provide a solid composite cathode structure; and, (g) optionally heating the composite cathode structure of step (f) to a temperature of 100° C. or greater.
Claim 38
Dependent Claim
139 words
A method for preparing a composite cathode according to claim 1, said method comprising the steps of: (a) dissolving said electroactive transition metal chalcogenide in a liquid medium; (b) contacting the composition resulting from step (a) with a gelling agent, thereby forming a sol-gel; (c) adding to the composition resulting from step (b) said electroactive sulfur-containing cathode material; (d) mixing the composition resulting from step (c) to dissolve or disperse said electroactive sulfur-containing cathode material; (e) casting the composition resulting from step (d) onto a suitable substrate or placing the composition resulting from step (d) into a mold; (f) removing some or all of the liquid from the composition resulting from step (e) to provide a solid composite cathode structure; and, (g) optionally heating the composite cathode structure of step (f) to a temperature of 100° C. or greater.
Claim 39
Dependent Claim
105 words
A method for preparing a composite cathode according to claim 1, said method comprising the steps of: (a) coating a current collector substrate with a composition comprising said electroactive sulfur-containing cathode material and drying or curing said composition to form a solid electroactive cathode layer on said current collector substrate; (b) dissolving or dispersing said electroactive transition metal chalcogenide in a liquid medium; and, (c) coating said electroactive cathode layer with the composition resulting from step (b) and drying or curing said composition to form a solid layer of said electroactive transition metal chalcogenide composition which covers the outer surface of said electroactive cathode layer.
Claim 40
Dependent Claim
121 words
A method for preparing a composite cathode according to claim 1, said method comprising the steps of: (a) coating a current collector substrate with a composition comprising said electroactive sulfur-containing cathode material and drying or curing said composition to form a solid electroactive cathode layer on said current collector substrate; (b) dissolving or dispersing said electroactive transition metal chalcogenide in a liquid medium; (c) contacting the composition resulting from step (b) with a gelling agent, thereby forming a sol-gel; and, (d) coating said electroactive cathode layer with the composition resulting from step (c) and drying or curing said composition to form a solid layer of said electroactive transition metal chalcogenide composition which covers the outer surface of said electroactive cathode layer.
Claim 41
Dependent Claim
28 words
An electric current producing cell comprising: (a) an anode; (b) a composite cathode according to claim 1; and, (c) an electrolyte between said anode and said composite cathode.
Claim 42
Dependent Claim
40 words
The cell according to claim 40, wherein said cell has an increase of specific capacity of greater than 150 mAh per gram of said electroactive transition metal chalcogenide, with respect to the specific capacity of said electroactive sulfur-containing cathode material.
Claim 43
Dependent Claim
40 words
The cell according to claim 40, wherein said cell has an increase of specific capacity of greater than 200 mAh per gram of said electroactive transition metal chalcogenide, with respect to the specific capacity of said electroactive sulfur-containing cathode material.
Claim 44
Dependent Claim
40 words
The cell according to claim 40, wherein said cell has an increase of specific capacity of greater than 300 mAh per gram of said electroactive transition metal chalcogenide, with respect to the specific capacity of said electroactive sulfur-containing cathode material.
Claim 45
Dependent Claim
41 words
The cell according to claim 40, wherein said anode comprises one or more materials selected from the group consisting of: lithium metal, lithium-aluminum alloys, lithium-tin alloys, lithium intercalated carbons, lithium intercalated graphites, calcium metal, aluminum metal, sodium metal, and sodium alloys.
Claim 46
Dependent Claim
29 words
The cell according to claim 40, wherein said electrolyte comprises one or more materials selected from the group consisting of: liquid electrolytes, gel polymer electrolytes, and solid polymer electrolytes.
Claim 47
Dependent Claim
60 words
The cell according to claim 40, wherein said electrolyte comprises: (a) one or more solid polymer electrolytes selected from the group consisting of: polyethers, polyethylene oxides, polyimides, polyphosphazenes, polyacrylonitriles, polysiloxanes, polyether grafted polysiloxanes; derivatives of the foregoing; copolymers of the foregoing; crosslinked and network structures of the foregoing; blends of the foregoing; and, (b) one or more ionic electrolyte salts.
Claim 48
Dependent Claim
104 words
The cell according to claim 40, wherein said electrolyte comprises: (a) one or more materials selected from the group consisting of: polyethylene oxides, polypropylene oxides, polyacrylonitriles, polysiloxanes, polyimides, polyethers, sulfonated polyimides, perfluorinated membranes, divinyl polyethylene glycols, polyethylene glycol-bis-(methyl acrylates), polyethylene glycol-bis(methyl methacrylates); derivatives of the foregoing; copolymers of the foregoing; crosslinked and network structures of the foregoing; blends of the foregoing; (b) one or more gel forming agents selected from the group consisting of: ethylene carbonate, propylene carbonate, N-methyl acetamide, acetonitrile, sulfolane, polyethylene glycols, 1,3-dioxolanes, glymes, siloxanes, and ethylene oxide grafted siloxanes; blends of the foregoing; and, (c) one or more ionic electrolyte salts.
Claim 49
Dependent Claim
55 words
The cell according to claim 47, wherein said gel-forming agent is a material of the following formula: ##STR7## wherein o is an integer equal to or greater than 1; p is an integer equal to or greater than 0 and less than about 30; and, the ratio t/s is equal to or greater than 0.
Claim 50
Dependent Claim
52 words
The cell according to claim 40, wherein said electrolyte comprises: (a) one or more electrolyte solvents selected from the group consisting of: ethylene carbonate, propylene carbonate, N-methyl acetamide, acetonitrile, sulfolane, polyethylene glycols, 1,3-dioxolanes, glymes, siloxanes, and ethylene oxide grafted siloxanes; blends of the foregoing; and, (b) one or more ionic electrolyte salts.
Claim 51
Dependent Claim
68 words
The cell according to claim 40, wherein said electrolyte comprises one or more ionic electrolyte salts selected from the group consisting of: MClO 4 , MAsF 6 , MSO 3 CF 3 , MSO 3 CH 3 , MBF 4 , MB(Ph) 4 , MPF 6 , MC(SO 2 CF 3 ) 3 , MN(SO 2 CF 3 ) 2 , ##STR8## where M is Li or Na.
Claim 52
Dependent Claim
40 words
A method of forming an electric current producing cell, said method comprising the steps of: (a) providing an anode; (b) providing a composite cathode according to claim 1; and, (c) interposing an electrolyte between said anode and said composite cathode.
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2002-07-05 | 2003-01-04 | 2003-07-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-07-05 | 2007-01-04 | 2007-07-06 | $3760.00 | Window Closed / Lapsed |
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