HYBRID ELECTRODES WITH BOTH INTERCALATION AND CONVERSION MATERIALS

Abstract

The disclosure set forth herein is directed to battery devices and methods therefor. More specifically, embodiments of the instant disclosure provide a battery electrode that comprises both intercalation chemistry material and conversion chemistry material, which can be used in automotive applications. There are other embodiments as well.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/944,502, filed Feb. 25, 2014, entitled HYBRID ELECTRODES WITH BOTH INTERCALATION AND CONVERSION MATERIALS, and U.S. Provisional Patent Application No. 62/027,908, filed Jul. 23, 2014, entitled HYBRID ELECTRODES WITH BOTH INTERCALATION AND CONVERSION MATERIALS. Each of these provisional patent applications is incorporated by reference herein for all purposes in their entirety.

BACKGROUND OF THE INVENTION

Recently, with the shortage of fossil-fuels and an increasing awareness of the adverse environmental effects from consuming fossil-fuels, public and private sectors have researched alternative and environmentally friendly technologies for storing and delivering energy, some of which include rechargeable batteries (i.e., secondary batteries, e.g., traction batteries). While many types of rechargeable batteries have been developed, the respective advantages and disadvantages of each type has prevented the widespread commercialization of rechargeable batteries in many applications, particularly automotive applications (e.g., electric and hybrid vehicles), in part due to an inability to tailor the energy, power, cycle-ability, and cost considerations for a given battery to a given application.

The suitability of a particular battery type(s) for a commercial application depends on the battery's physical and performance characteristics as well as the cost of the constituent materials and the associated methods of assembly. For automotive (e.g., electric and hybrid vehicles) applications, high power and energy capacity, wide voltage operation range, and mechanical durability are all desirable characteristics, but unfortunately many conventional battery devices are insufficient in at least one of these respects for current and future automotive demands. For electric automobiles, batteries need to demonstrate both high energy density for long range driving and also high instantaneous power output for acceleration and/or braking scenarios. Since most high energy density batteries lack high power output capabilities, conventional rechargeable batteries have not been widely adopted for automotive applications. Therefore, new and improved battery devices and methods of making and using the same are needed in the field to which the instant disclosure pertains.

BRIEF SUMMARY OF THE INVENTION

The disclosure herein sets forth positive electrode compositions for electrochemical cells which include more than one type of positive electrode active material. In some embodiments, these electrodes include a conversion chemistry active material and an intercalation chemistry active material. In some of these embodiments, the intercalation voltage for the intercalation material may be above the conversion voltage for the conversion chemistry material, in which case the intercalation chemistry is utilized during recharge to provide a voltage ceiling. In some other embodiments, the intercalation voltage for the intercalation material may be below the conversion voltage for the conversion chemistry material, in which case the intercalation chemistry is utilized during discharge to provide a voltage floor. In certain embodiments, the upper operating voltage plateau (i.e., Voltage v. Li at full charge) of the conversion chemistry active material is below the operating voltage plateau for the intercalation chemistry active material, in which case the intercalation material provides a voltage ceiling when the electrochemical cell recharges. In certain embodiments, the upper operating voltage plateau (i.e., Voltage v. Li at full charge) of the conversion chemistry active material is between the upper operating voltage plateau and lower operating voltage plateau for the intercalation chemistry active material, in which case the intercalation material provides a voltage ceiling when the electrochemical cell recharges. In certain other embodiments, the lower operating voltage plateau (i.e., lower voltage limit, Voltage v. Li when discharged) of the intercalation chemistry active material is above the lower operating voltage plateau for the intercalation chemistry active material, in which case the intercalation material provides a voltage floor when the electrochemical cell discharges. In certain other embodiments, the operating voltage plateau (i.e., lower voltage limit, Voltage v. Li when discharged) of the intercalation chemistry active material is between the upper operating voltage plateau and the lower operating voltage plateau for the intercalation chemistry active material, in which case the intercalation material provides a voltage floor when the electrochemical cell discharges. In certain embodiments, the intercalation chemistry materials that are mixed with conversion chemistry material operate at a higher voltage than the intercalation regime voltage range for the conversion chemistry material. In certain other embodiments, the intercalation chemistry materials that are mixed with conversion chemistry materials operate at a lower voltage than the conversion regime voltage range for the conversion chemistry material. In yet other embodiments, the intercalation chemistry materials that are mixed with conversion chemistry materials operate at both a higher voltage than the intercalation regime voltage range for the conversion chemistry material and at a lower voltage than the conversion regime voltage range for the conversion chemistry active materials. Also set forth herein are methods of making and using these positive electrodes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a diagram illustrating a cathode (i.e., positive electrode) active material including randomly mixed intercalation chemistry materials and conversion chemistry materials.

FIG. 2 shows a diagram illustrating a cathode with a graded composition.

FIGS. 3A-C show diagrams illustrating a low temperature acceleration operation for an electrochemical cell having a positive electrode which includes either iron trifluoride (FeF₃), only, or both iron trifluoride (FeF₃) and lithium titanate (Li₄Ti₅O₁₂, i.e., LTO) positive electrode active materials.

FIGS. 4A-C show diagrams illustrating a low temperature regenerative braking operation for an electrochemical cell having a positive electrode which includes either iron trifluoride (FeF₃), only, or both iron trifluoride (FeF₃) and lithium titanate (Li_4-7Ti₅O₁₂, i.e., LTO) positive electrode active materials.

FIGS. 5A-E illustrate a variety of operating scenarios for electrochemical cells having positive electrodes which include mixtures of intercalation chemistry active materials and conversion chemistry active materials.

FIG. 6 is a table illustrating operating voltages for different materials suitable for use in conversion chemistry reactions.

FIG. 7 is a diagram illustrating an example battery cell which includes a hybrid electrode having a conversion chemistry active material and two types of intercalation chemistry active materials according to an embodiment set forth in this disclosure.

FIG. 8 shows an example double sided cathode electrode suitable for use with a battery device embodiment set forth herein.

FIGS. 9A-F show a list of intercalation materials and their corresponding average voltage (between about 1.3-2.5V), for the intercalated amount of Li noted in the Li subscript, that are suitable for use with the positive electrode active materials, e.g., conversion chemistry materials, also set forth herein.

FIGS. 10A-F show a list of intercalation materials and their corresponding average voltage (between about 2.5-3.8V) for the intercalated amount of Li noted in the Li subscript that are suitable for use with the positive electrode active materials, e.g., conversion chemistry materials, also set forth herein.

FIG. 11 shows overlaid plots of Voltage v. Discharge Run Time, and Current v. Discharge Run Time, for electrochemical cells having either FeF₃ positive electrode active materials, only, or a 80:20 combination of iron trifluoride (FeF₃) and lithium titanate (LTO, i.e., Li_4-7Ti_5.5O₁₂) positive electrode active materials. Cells were discharged at C/10 at 50° C.

FIG. 12 shows an overlaid plot of Voltage v. Run active mass-specific capacity (mAh/g), and Current v. Run active mass-specific capacity (mAh/g), for electrochemical cells having either FeF₃ positive electrode active materials, only, or a 80:20 combination of iron trifluoride (FeF₃) and lithium titanate (LTO, i.e., Li_4-7Ti_5.5O₁₂) positive electrode active materials.

FIG. 13 shows an overlaid plot of Voltage v. Run Time for electrochemical cells having either FeF₃ positive electrode active materials, only, or a 80:20 combination of iron trifluoride (FeF₃) (labeled as control-1 and control-2) and lithium titanate (LTO, i.e., Li_4-7Ti_5.5O₁₂) positive electrode active materials (labeled as LTO-1 and LTO-2).

FIG. 14 shows a magnified perspective of FIG. 13 and compares to LTO-1 and control-1.

FIG. 15 shows an overlaid plot of Area Specific Resistance (ASR) v. charge-discharge Pulses for ten (10) for electrochemical cells having either FeF₃ positive electrode active materials or a 80:20 combination of iron trifluoride (FeF₃) (labeled as control-1 through control-4) and lithium titanate (LTO, i.e., Li₄Ti_5.5O₁₂) positive electrode active materials (labeled as LTO-1 through LTO-6).

FIG. 16 shows a plot of Voltage (v. Li) as a function of Run time (103 seconds) for electrochemical cells having either FeF₃ positive electrode active materials, only, or a 80:20 combination of iron trifluoride (FeF₃) and lithium titanate (LTO, i.e., Li_4-7Ti_5.5O₁₂) positive electrode active materials.

FIG. 17 shows a magnified perspective of FIG. 16.

FIG. 18 shows a magnified perspective of FIG. 16.

FIG. 19 illustrates a battery power demand scenario as a function of time for an accelerating electric vehicle.

FIG. 20 shows a simulated voltage response plot of electrochemical cell Voltage (V v. Li) as a function of time for electrochemical cells having LTO positive electrode active materials, FeF₃ positive electrode active materials, or a 95:5 w/w mixture of FeF₃ and LTO positive electrode active materials based on the power demand scenario in FIG. 19.

FIG. 21 shows a battery power demand scenario as a function of time for a regeneratively braking electric vehicle.

FIG. 22 shows a simulated voltage response plot of electrochemical cell Voltage (V v. Li) as a function of time for electrochemical cells having LTO positive electrode active materials, FeF₃ positive electrode active materials, or a 95:5 w/w mixture of FeF₃ and LTO positive electrode active materials based on the power demand scenario in FIG. 21.

FIG. 23 shows an example electrochemical cell including a hybrid positive electrode according to an embodiment set forth in this disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

As used herein, the phrase “active material,” “active electrode material,” or “active material,” refers to a material that is suitable for use in a lithium rechargeable battery cell and that is responsible for delivering or receiving lithium ions during the charging and discharging cycles of the battery cell. The active material may undergo a chemical reaction during the charging and discharging cycles. The same battery cell may include a positive active material and a negative active material. For examples, a positive active material may include a metal fluoride that converts to a metal and lithium fluoride during the discharge cycle of the battery cell containing this material.

As used herein, the phrase “at least one member selected from the group,” includes a single member from the group, more than one member from the group, or a combination of members from the group. At least one member selected from the group consisting of A, B, and C includes, for example, A, only, B, only, or C, only, as well as A and B as well as A and C as well as B and C as well as A, B, and C or any other all combinations of A, B, and C.

As used herein, a “binder” refers to a material that assists in the adhesion of another material. Binders useful in the present invention include, but are not limited to, polypropylene (PP), atactic polypropylene (aPP), isotactive polypropylene (iPP), ethylene propylene rubber (EPR), ethylene pentene copolymer (EPC), polyisobutylene (PIB), styrene butadiene rubber (SBR), polyolefins, polyethylene-co-poly-1-octene (PE-co-PO), PE-co-poly(methylene cyclopentane) (PE-co-PMCP), stereoblock polypropylenes, polypropylene polymethylpentene copolymer, polyethylene oxide (PEO), PEO block copolymers, silicone, and the like.

As used herein, the terms “cathode” and “anode” refer to the electrodes of a battery. During a charge cycle in a Li-secondary battery, Li ions leave the cathode and move through an electrolyte and to the anode. During a charge cycle, electrons leave the cathode and move through an external circuit to the anode. During a discharge cycle in a Li-secondary battery, Li ions migrate towards the cathode through an electrolyte and from the anode. During a discharge cycle, electrons leave the anode and move through an external circuit to the cathode. As used herein, the cathode region is the physical area of the electrochemical cell comprising the cathode.

As used herein, the anode region is the physical area of the electrochemical cell comprising the anode. As used herein, the electrolyte region is the physical area of the electrochemical cell electrolyte the cathode. As used herein, the term “electrolyte” refers to a material that allows ions, e.g., Li⁺, to migrate therethrough but which does not allow electrons to conduct therethrough. Electrolytes are useful for electrically isolating the cathode and anodes of a secondary battery while allowing ions, e.g., Li⁺, to transmit through the electrolyte. As used herein, the term “electrolyte,” also refers to an ionically conductive and electrically insulating material. Solid electrolytes, in particular, rely on ion hopping through rigid structures. Solid electrolytes may be also referred to as fast ion conductors or super-ionic conductors. Solid electrolytes may be also used for electrically insulating the positive and negative electrodes of a cell while allowing for the conduction of ions, e.g., Li+, through the electrolyte. In this case, a solid electrolyte layer may be also referred to as a solid electrolyte separator. Some electrolytes suitable for use herein include, but are not limited to Li₂S—SiS₂, Li—SiS₂, Li—S—Si, and/or a catholyte consisting essentially of Li, S, and Si, Li_xSi_yS_z where 0.33≤x≤0.5, 0.1≤y≤0.2, 0.4≤z≤0.55, which may include up to 10 atomic % oxygen, a mixture of Li₂S and SiS₂, in which the ratio of Li₂S:SiS₂ is 90:10, 85:15, 80:20, 75:25, 70:30, 2:1, 65:35, 60:40, 55:45, or 50:50 molar ratio, Li₂S—SnS₂, Li₂S—SnS, Li—S—Sn, and/or a catholyte consisting essentially of Li, S, and Sn, Li_xSn_yS_z where 0.25≤x≤0.65, 0.05≤y≤0.2, and 0.25≤z≤0.65, a mixture of Li₂S and SnS₂ in the ratio of 80:20, 75:25, 70:30, 2:1, or 1:1 molar ratio, which may include up to 10 atomic % oxygen and/or may be doped with Bi, Sb, As, P, B, Al, Ge, Ga, and/or In. Other suitable electrolytes are found, for example, in International Patent Application No. PCT/US2014/038283, filed May 16, 2014, and entitled SOLID STATE CATHOLYTE OR ELECTROLYTE FOR BATTERY USING LI_AMP_BS_C (M═Si, Ge, AND/OR Sn), which is incorporated by reference herein in its entirety. Other suitable electrolytes include Li_xP_yS, where 0.33≤x≤0.67, 0.07≤y≤0.2 and 0.4≤z≤0.55, or a mixture of Li₂S:P₂S; wherein the molar ratio is 10:1, 9:1, 8:1, 7:1, 6:1 5:1, 4:1, 3:1, 7:3, 2:1, or 1:1, also Li_xP_yS_zO_w where 0.33≤x≤0.67, 0.07≤y≤0.2, 0.4≤z≤0.55, 0≤w≤0.15. Other suitable electrolytes include Li-stuffed garnet oxides that are characterized by a crystal structure related to a garnet crystal structure. Li-stuffed garnets include compounds having the formula Li_aLa_bM′_cM″_dZr_eO_f, Li_aLa_bM′_cM″_dTa_cO_f, or Li_aLa_bM′_cM″_dNb_cO_f, where 4<a<8.5, 1.5<b<4, 0≤c≤2, 0≤d≤2; 0≤e<2, 10<f<13, and M′ and M″ are, independently in each instance, selected from Al, Mo, W. Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, or Ta, or Li_aLa_bZr_eAl_dMe″_eO_f, where 5<a<7.7, 2<b<4, 0<c≤2.5, 0≤d<2, 0≤e<2, 10<f<13 and Me″ is a metal selected from Nb, Ta, V, W, Mo, or Sb and as described herein. “Garnets,” as used herein, also include those garnets described above that are doped with Al₂O₃. Garnets, as used herein, also include those garnets described above that are doped so that Al³⁺ substitutes for Li⁺. As used herein, Li-stuffed garnets, and garnets, generally, include, but are not limited to, Li_7.0 La₃(Zr_t1+Nb₁₂+Ta₁₃)O₁₂+0.35Al₂O₃, wherein (t1+t2+t3=subscript 2) so that the La:(Zr/Nb/Ta) ratio is 3:2. Also, garnet and lithium-stuffed garnets as used herein can include Li_xLa₃Zr₂O₁₂+yAl₂O₃, where x ranges from 5.5 to 9 and y ranges from 0 to 1. In some embodiments, x is 7 and y is 1.0. In some embodiments, x is 7 and y is 0.35. In some embodiments, x is 7 and y is 0.7. In some embodiments x is 7 and y is 0.4. Also, garnets as used herein can include Li_xLa₃Zr₂O₁₂+yAl₂O₃. Exemplary lithium-stuffed garnets are found in the compositions set forth in International Patent Application Nos. PCT/US2014/059575 and PCT/US2014/059578, filed Oct. 7, 2014, entitled GARNET MATERIALS FOR LI SECONDARY BATTERIES AND METHODS OF MAKING AND USING GARNET MATERIALS.

As used herein, the phrase “conversion chemistry active material,” or “conversion chemistry material” refers to a material that undergoes a chemical reaction during the charging and discharging cycles of a secondary battery. Conversion chemistry materials useful in the present invention include, but are not limited to, LiF, Fe, Cu, Ni, FeF₂, FeO_dF_3-2d, FeF₃, CoF₃, CoF₂, CuF₂, NiF₂, where 0≤d≤0.5, and the like. Exemplary conversion chemistry materials are found, for example, in U.S. Patent Publication No. 2014/0117291, filed Oct. 25, 2013, and entitled METAL FLUORIDE COMPOSITIONS FOR SELF FORMED BATTERIES, and in U.S. Provisional Patent Application No. 62/038,059, filed Aug. 15, 2014, entitled DOPED CONVERSION MATERIALS FOR SECONDARY BATTERY CATHODES, all of which are incorporated by reference herein in their entirety. Exemplary conversion chemistry materials are found, for example, in U.S. Patent Application Publication No. 2014/0170493, entitled NANOSTRUCTURED MATERIALS FOR ELECTROCHEMICAL CONVERSION REACTIONS, and filed Jun. 19, 2013 as U.S. patent application Ser. No. 13/922,214, the contents of which are incorporated by reference in their entirety.

As used herein, the term “C-rate” of C/1 is defined as a constant current cycle where the nameplate capacity is discharged in one hour. A C-rate of C/X is defined in reference to that rate, where the charge and discharge current is 1/X of that at C/1, approximately corresponding to a full discharge at constant current in X hours.

As used herein, the phrase “intercalation chemistry material,” or “intercalation chemistry active material,” refers to a material that undergoes a lithium insertion, reaction during the charging and discharging cycles of a secondary battery. For example, intercalation chemistry materials include LiFePO₄ and LiCoO₂. In these materials, Li⁺ inserts into and also deintercalates out of the intercalation material during the discharging and charging cycles of a secondary battery.

As used herein, a “metal fluoride” (MF) refers to a material including a metal component and a fluorine (F) component. A MF can optionally include a lithium (Li) component. In the charged state, the MF includes a fluoride of a metal which can convert into a lithium fluoride salt and a reduced metal, in the discharged state. For example, the charged state MF can convert to a metal and lithium fluoride during discharge of a battery in accordance with the following reaction: Li+MF→LiF+M. MFs useful with the disclosure herein include, but are not limited to, LiF, Li_zFeF₃, Li_zCuF₂, Li_zNiF₂, Li_zCoF₂, Li_zCoF₃, Li_zMnF₂, Li_zMnF₃, where 0≤z≤3, and the like. In some embodiments, the MF can be nanodimensioned and, in some embodiments, the MF is in the form of nanodomains. In some embodiments, the MF can be LiF and can further include a nanodimensioned metal including, Fe, Co, Mn, Cu, Ni, Zr, or combinations thereof. MFs useful in the present invention include those set forth in U.S. Patent Application Publication No. 2014/0170493, entitled NANOSTRUCTURED MATERIALS FOR ELECTROCHEMICAL CONVERSION REACTIONS, and filed Jun. 19, 2013 as U.S. patent application Ser. No. 13/922,214, the contents of which are incorporated by reference in their entirety. MFs useful in the present invention also include those set forth in U.S. Provisional Patent Application No. 62/038,059, entitled: DOPED CONVERSION MATERIALS FOR SECONDARY BATTERY CATHODES, and filed Aug. 15, 2014, the contents of which are incorporated by reference in their entirety.

As used herein, the phrase “positive electrode” refers to the electrode in a secondary battery towards which positive ions, e.g., Li+, conduct, flow or move during discharge of the battery. As used herein, the phrase “negative electrode” refers to the electrode in a secondary battery from where positive ions, e.g., Li+, flow or move during discharge of the battery. In a battery comprised of a Li-metal electrode and a conversion chemistry electrode (i.e., active material; e.g., NiF_x), the electrode having the conversion chemistry materials is referred to as the positive electrode. In some common usages, cathode is used in place of positive electrode, and anode is used in place of negative electrode. When a Li-secondary battery is charged, Li ions move from the positive electrode (e.g., NiF_x) towards the negative electrode (Li-metal). When a Li-secondary battery is discharged, Li ions move towards the positive electrode (e.g., NiF_x; i.e., cathode) and from the negative electrode (e.g., Li-metal; i.e., anode).

As used herein, the term “catholyte” refers to an ion conductor that is intimately mixed with, or that surrounds, or that contacts the positive electrode active material. Catholytes include those catholytes set forth in International PCT Patent Application No. PCT/US14/38283, entitled SOLID STATE CATHOLYTE OR ELECTROLYTE FOR BATTERY USING Li_AMP_BS_C (M═Si, Ge, AND/OR Sn), filed May 15, 2014, the contents of which are incorporated by reference in their entirety. Catholytes include those catholytes set forth in International PCT Patent Application No. PCT/US2014/059575, entitled GARNET MATERIALS FOR LI SECONDARY BATTERIES AND METHODS OF MAKING AND USING GARNET MATERIALS, filed Oct. 7, 2014, the contents of which are incorporated by reference in their entirety.

As used herein, the phrase “about 70% w/w,” refers to a range that includes ±10% around the number qualified by the word about. For example, about 70 includes 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, or 77. For example, about 30 includes 27, 28, 29, 30, 31, 32, or 33.

As used herein, the phrase “substantially segregated,” refers to a layered material in which there is an observable distinction between one material which is separate in space from another material. In some examples, when two or more materials are substantially segregated, these materials are separated in space or segregated from each other.

As used herein, the phrase “proximate to” refers to the relative position of two or more materials and means that the material which is proximate to another material is closest to that another material.

As used herein, the phrase “providing” refers to the provision of, generation or, presentation of, or delivery of that which is provided. Providing includes making something available. For example, providing LiF refers to the process of making LiF available, or delivering LiF, such that LiF can be used as set forth in a method described herein.

The disclosure herein is directed to battery devices and their constituent components as well as methods of making and using the same. More specifically, embodiments set forth herein provide a battery electrode (e.g., a positive electrode) that comprises both intercalation chemistry materials and conversion chemistry materials, which can be used in automotive applications. There are other embodiments as well.

The following description is presented to enable one of ordinary skill in the art to make and use devices and components set forth herein and to incorporate them in the context of particular applications. Various modifications, as well as a variety of uses in different applications will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to a wide range of embodiments. Thus, the instant disclosure is not intended to be limited to the embodiments presented, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

In the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure set forth herein. However, it will be apparent to one skilled in the art that the instant disclosure may be practiced without necessarily being limited to these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the disclosure set forth herein.

The reader's attention is directed to all papers and documents which are filed concurrently with this specification and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. All the features disclosed in this specification, (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

Furthermore, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of” or “act of” in the Claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.

Please note, if used, the labels left, right, front, back, top, bottom, forward, reverse, clockwise and counter clockwise have been used for convenience purposes only and are not intended to imply any particular fixed direction. Instead, they are used to reflect relative locations and/or directions between various portions of an object.

Under most common operating conditions (e.g., temperature above 0° C.), secondary energy storage devices that rely on conversion chemistry cathodes can provide higher energy density and better performance than batteries with intercalation chemistry cathodes. For example, conversion chemistry cathodes can provide an energy density of over 1000 mWh/g. In addition, certain types of conversion chemistry cathode can operate at high temperature level (e.g., over 50° C., or over 80° C., or over 100° C.). For example, conversion chemistry material and processes thereof are described in U.S. patent application Ser. No. 13/922,214, filed Jun. 19, 2013, entitled NANOSTRUCTURED MATERIALS FOR ELECTROCHEMICAL CONVERSION REACTIONS, which is incorporated by reference herein in its entirety for all purposes. For example, conversion chemistry materials and processes thereof are described in U.S. Provisional Patent Application No. 62/038,059, filed Aug. 15, 2014, entitled DOPED CONVERSION MATERIALS FOR SECONDARY BATTERY CATHODES, and in U.S. Provisional Patent Application No. 62/043,353, filed Aug. 28, 2014, entitled DOPED CONVERSION MATERIALS FOR SECONDARY BATTERY CATHODES, both provisional patent applications of which are incorporated by reference herein in their entirety for all purposes.

There are specific performance characteristics and operating conditions for conversion chemistry cathodes. According to implementations of the disclosure herein, a cathode (i.e., positive electrode) may include active material particles with fast kinetics (high power capability) and active material particles with slower kinetics but high energy density. A conversion chemistry cathode can provide a high level of energy density, but in some conditions, low power density. For instance, at low temperature (<0° C. for example), a conversion material may have a low power density compared to an intercalation material. In comparison, an intercalation chemistry cathode typically has relatively low energy density, but relatively high power density.

Thus it is to be appreciated that embodiments disclosed herein provide positive electrodes that include conversion chemistry particles of high energy density (e.g., FeF₂, FeO_xF_3-2x, FeF₃, CoF₃, CuF₂, NiF₂, etc.), with intercalation oxide particles (e.g., LiMPO₄(M═Fe, Ni, Co, Mn), Li_xTi_yO_z, wherein x is from 0 to 8, y is from 1 to 12, z is from 1 to 24, LiMn₂O₄, LiMn_2-aNi_aO₄, wherein a is from 0 to 2, LiCoO₂, Li(NiCoMn)O₂, Li(NiCoAl)O₂, Nickel Cobalt Aluminum Oxides [NCA], and related intercalation oxides). Additional intercalation oxide particles are found in U.S. Provisional Patent Application No. 62/096,510, entitled LITHIUM RICH NICKEL MANGAGESE OXIDE, filed Dec. 23, 2014, the contents of which are herein incorporated by reference in its entirety for all purposes. To obtain desired performance, conversion and intercalation materials are mixed (e.g., homogeneously or heterogeneously depending on the application), layered, multilayered, or graded, and operated according to the methods set forth herein. For example, under conditions of pulse (high power demand) regenerative charge or pulse discharge, the power may be drawn from the intercalation chemistry active materials. Depending on the materials selected and co-formulated, the intercalation voltage may be above or below the conversion voltage. If above, the intercalation chemistry is utilized during recharge to provide a voltage ceiling, and if below, the intercalation chemistry is utilized during discharge to provide a voltage floor. Detailed descriptions are provided below.

Depending on the implementation, intercalation and conversion materials can be mixed in various ways. FIG. 1 is a simplified diagram illustrating a cathode material comprising randomly mixed intercalation material and conversion material according to an embodiment of the disclosure set forth herein. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. In FIG. 1, shaded circles represent intercalation material particles, and the unshaded circles represent conversion material particles. For automotive applications, where batteries are used to power electric vehicles (or hybrid vehicles with electric motors), the energy capacity is often more important than power capacity for most operations. As such, in some examples herein, the conversion chemistry materials, which have a relatively higher energy capacity than intercalation materials, are formulated as the majority component in a hybrid positive electrode which includes both conversion chemistry materials and intercalation chemistry materials. For example, as shown in FIG. 1, a smaller quantity of intercalation chemistry material is provided than the conversion chemistry material. In some examples, the composition of a cathode materials set forth herein has less than 20% intercalation material with the remaining percentage being the conversion chemistry material. Depending on the implementation, ratios between intercalation material and conversion material may vary.

In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 99:1. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 98:2. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 97:3. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 96:4. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 95:5. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 94:6. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 93:7. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 92:8. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 91:9. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 90:10. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 89:11. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 88:12. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 87:13. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 86:14. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 85:15. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 84:16. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 83:17. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 82:18. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 81:19. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 80:20. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 79:21. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 78:22. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 77:23. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 76:24. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 75:15. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 74:26. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 73:27. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 72:28. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 71:29. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 70:30. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 69:31. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 68:32. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 67:33. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 66:34. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 65:35. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 64:36. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 63:37. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 62:38. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 61:39. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 60:40. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 59:41. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 58:42. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 57:43. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 56:44. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 55:45. In some other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 54:46. In other examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 53:47. In certain examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 52:48. In some examples, the respective volume ratio of conversion chemistry active material to intercalation chemistry active material is 51:49.

In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 99:1. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 98:2. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 97:3. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 96:4. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 95:5. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 94:6. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 93:7. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 92:8. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 91:9. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 90:10. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 89:11. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 88:12. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 87:13. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 86:14. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 85:15. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 84:16. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 83:17. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 82:18. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 81:19. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 80:20. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 79:21. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 78:22. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 77:23. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 76:24. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 75:15. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 74:26. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 73:27. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 72:28. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 71:29. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 70:30. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 69:31. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 68:32. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 67:33. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 66:34. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 65:35. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 64:36. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 63:37. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 62:38. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 61:39. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 60:40. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 59:41. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 58:42. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 57:43. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 56:44. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 55:45. In some other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 54:46. In other examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 53:47. In certain examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 52:48. In some examples, the respective weight ratio of conversion chemistry active material to intercalation chemistry active material is 51:49.

The mixing of intercalation and conversion materials varies. For example, FIG. 1 shows substantially random mixing of intercalation and conversion materials. FIG. 2 is a simplified diagram illustrating a cathode with graded composition according to an embodiment of the disclosure set forth herein. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. In FIG. 2, shaded circles represent intercalation material particles, and the unshaded circles represent conversion material particles. The intercalation chemistry material is in much smaller amount relative to the conversion chemistry material, and is positioned on the top region of the cathode (i.e., the region of the cathode which interfaces with or is most proximal to the electrolyte). For example, by positioning intercalation materials close to the electrolyte, the intercalation material may be accessed at higher rates as compared to the conversion chemistry material when the electrochemical cell is charging or discharging and lithium ions move through the electrolyte into or out of the cathode. In various discharging implementations, the intercalation materials are positioned to react with incoming lithium ions before these ions reacts with the conversion chemistry materials in the cathode. For example, in various automotive related applications, power capacity is important when starting an electric vehicle at low temperatures and during pulse discharging for electric vehicle acceleration. In these example high power capacity examples, the intercalation materials most proximal to the electrolyte will be the first material in the cathode to react with lithium ions, and before these ions react with the conversion chemistry materials.

In some examples, provided is an electrochemical cell in which the intercalation chemistry active materials in the hybrid positive electrode are closer to, or proximal to, the electrolyte which separates the positive and negative electrodes that is the conversion chemistry active materials.

In certain embodiments, conversion chemistry and intercalation chemistry materials are arranged in layers. In the case of a graded or layered mixture, the graded chemistry can be fabricated by slurry coating in a dual pass coater, and other processes are possible as well. For example, if the particles are a different size or density, the particles may be made to preferentially segregate in the slurry during deposition and/or drying.

In certain embodiments, conversion chemistry and intercalation chemistry materials are arranged in layers. In some examples, the layer in direct contact with the electrolyte is the intercalation material and the conversion chemistry material is in direct contact with the intercalation material but not in direct contact with the electrolyte. In some other examples, the layer in direct contact with the electrolyte is the conversion chemistry material and the intercalation chemistry material is in direct contact with the intercalation material but not in direct contact with the electrolyte.

In certain embodiments, the positive electrode includes alternating layers of intercalation and conversion chemistry active materials, in which the layer most proximal to the electrolyte is the intercalation material. In certain other embodiments, the positive electrode includes alternating layers of intercalation and conversion chemistry active materials, in which the layer most proximal to the electrolyte is the conversion chemistry material.

As a cathode material, conversion chemistry material can provide much higher energy density than intercalation chemistry material. For the most part, it is desirable to have as much conversion chemistry material in the cathode as possible. The use of intercalation chemistry material is for specific purposes in electric vehicle applications, such as regenerative braking, lower temperature start up, and acceleration. In portable devices as well, low temperature operation may benefit from the introduction of an intercalation material in a predominantly conversion cathode.

As an example, cathodes with mixed intercalation and conversion chemistry are especially useful in EV regenerative braking application, especially in cold weather. In low temperature operating environment, conversion chemistry material may have low power capability. The intercalation chemistry material, which is implemented as a part of cathodes, can provide the pulse power in this condition. In addition, intercalation chemistry material can be very useful during EV acceleration, where stored electricity is quickly discharged, and the intercalation chemistry material can provide the needed pulse power.

In various implementations, the cathode chemistry is specifically configured to power the electric vehicle and works in accordance with the powertrain voltage parameters. For example, the power electronics of electric vehicles typically handle a voltage ratio from the floor to ceiling of 1.5 to 2.5. By including intercalation chemistry material (e.g., LTO material) with a discharge potential at just above 1.5V, the voltage floor can be raised from 1.3V to 1.5V, allowing a voltage ceiling of 2.5*1.5=3.75V instead of 2.5*1.3=3.25V. The increased voltage ceiling can provide operating freedom and power efficiency as needed for operating electric vehicles, especially under exacting conditions.

As explained above, conversion chemistry materials are characterized by a high level of energy capacity. Exemplary conversion chemistry materials include, but not limited to, FeF₂, FeO_xF_3-2x, FeF₃, CoF₃, CoF₂, BiF₃, CuF₂, MnF₃, NiF₂, and/or other high energy density conversion chemistry materials. In various implementations, conversion chemistry materials may be nanostructured materials that can provide an energy capacity of over 1000 mWh/g. The intercalation chemistry materials are characterized by a high level of power capacity. Exemplary intercalation chemistry materials include lithium titanate on the low voltage side, and on the high voltage side, lithium iron phosphate, a spinel, an olivine, LiCoO₂, NCM, NCA, and/or other higher voltage intercalation chemistry materials. Exemplary intercalation chemistry materials are included in the tables in FIGS. 9 and 10.

The following example illustrates how the fraction of intercalation material in a cathode composition may be calculated depending on a given battery use condition. It also illustrates that the amount of intercalation material required for extreme applications does not significantly diminish the energy density of the battery. An electric vehicle may require about 10 to 30 seconds of discharge pulse power of 3.5E at 0° C. A 3.5E rate means that the battery is providing power equivalent to 3.5 times the rated energy that would be obtained from a 1 hour continuous power draw (i.e., discharge) that would fully discharge the battery. The following example assumes a high power demand scenario of 30 second pulse in which the conversion chemistry material insufficiently supplies a fraction of the power demanded at this operating condition (temperature and rate). In this example, for a cell rated at 100 Wh, the pulse is a demand of roughly 3 Wh (3.5*100 W*30 s*1 hr/3600 s), or 3% of the cell energy. Therefore, 3% of the energy of active materials would be contributed in this architecture by the power chemistry. To work out the mass fraction contribution, if the cathode includes a discharge power chemistry comprising Li₄Ti₅O₁₂(LTO), which has a specific capacity of 165 mAh/g (including Li) and a 1.5V discharge potential. A 3 Wh contribution from LTO implies that the cell must include 2 Ah capacity of LTO (3 Wh/1.5V=2 Ah). If the 100 Wh cell includes 42 Ah of FeF₃ with a specific capacity of 601 mAh/g (including Li), then the mass fraction of LTO is 14% of total weight (i.e., 12.1 g vs 69.9 g). This example illustrates that a small fraction of the battery cathode may be comprised of the fast intercalation material, with the majority component of the cathode being a conversion chemistry material, and meet the high power demand contemplated in this example. Depending on the required operating conditions, the amount of intercalation material used varies.

In another example, a battery cathode composition includes a high voltage, fast intercalation cathode material co-formulated with the conversion material. In this example, the specification requires a 3E pulse charge for 10 seconds at 0° C. and the conversion material cannot deliver that charge rate, in which case an intercalation chemistry material can be formulated with the conversion chemistry material in order to meet the requirements of this scenario. If LiCoO₂ (LCO) is used (4V, 137 mAh/g specific capacity including lithium) as the intercalation chemistry material to deliver the 300 W for 10 seconds, then 208 mAh needs to be delivered from LCO. In this example, 1.5 g of LCO is included, or a mass fraction of about 2%. The mass fraction is lower in this example because a shorter pulse is required, and because the voltage of LCO is higher, so the specific energy is higher, and a smaller mass is required to deliver that energy. As demonstrated in the above two examples, the amount and types of intercalation material used depends on many factors, such as characteristics of the intercalation chemistry material, conversion chemistry material, expected operating condition, desired tolerance, energy and power requirements of electric vehicles, and other factors.

For certain example electric vehicle applications, the high voltage intercalation chemistry materials has a charge voltage greater than the low rate, high temperature charge potential of the conversion chemistry material (e.g., around 3.7V in the case of FeF₃), but lower than the system high voltage cutoff (around 4.2V in some cases). Examples of high voltage materials that can be used are LiMPO₄(M═Co, Ni, Mn, Fe, and combinations thereof), LiNi_0.5Mn_1.5O₄, LiMn_0.5Ni_0.5O₂, LiMn₂O₄, LiCoO₂, and Li₃V₂PO₄. Additional high voltage materials are listed in FIGS. 10A-10F. Low-voltage intercalation chemistry materials are to have a discharge potential greater than the system low voltage cutoff (around 1.3V in some cases) but lower than the high temperature, low rate discharge potential of the conversion chemistry material (2.4V in the case of FeF₃). Examples of lower voltage materials that can be used are Li₄Ti₅O₁₂. Additional low voltage materials are listed in FIGS. 9A-9F. In some examples set forth herein, the conversion chemistry material is co-formulated with both a low-voltage intercalation chemistry material and also a high-voltage intercalation chemistry material. In some examples set forth herein, the conversion chemistry material is co-formulated with an intercalation chemistry material listed in the tables in FIGS. 9A-F and also with an intercalation chemistry material listed in the tables in FIGS. 10A-F.

As described above, the intercalation chemistry materials and conversion chemistry materials are synergistic in at least one respect. A low voltage intercalation chemistry material like LTO can provide the discharge energy on a discharge pulse (e.g., high power demand pulse or acceleration), and it can then be recharged by the conversion chemistry material (e.g., FeF₃) as the pulse completes. The processed can be used repeatedly, for each discharge pulse, so long as the discharge pulses are spaced sufficiently temporally apart to allow the low voltage intercalation chemistry material (e.g., LTO) to recharge. In a preferred embodiment, only enough LTO needs to be included in the hybrid positive electrode to provide energy for the single longest expected discharge pulse.

FIG. 3 is a simplified diagram illustrating operation of a mixed material cathode according to embodiments of the disclosure set forth herein at low temperature where the electric vehicle accelerates. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. FIG. 3A shows an example power demand of a vehicle at low temperature (e.g., 0 Celsius). FIG. 3B shows voltage output, as a function of time, for a battery cell comprising a conversion chemistry material (e.g., FeF₃ or other types of conversion chemistry material). FIG. 3C shows voltage output t, as a function of time, for a battery cell comprising both conversion chemistry materials and intercalation chemistry materials (e.g., LTO or other types of intercalation materials).

As shown in FIG. 3A, in some examples, the power demand for an electric vehicle is substantially constant, except when the electric vehicle accelerates at time 301A and 302A, when the power demand peaks. Depending on the state of charge, the battery cells for the electric vehicle may or may not have enough power to satisfy the power demand when the electric vehicle accelerates. As shown in FIG. 31B, the cell voltage of the battery cells for the electric vehicle gradually drops below the operating lower voltage cutoff, as the electric vehicle operates, from the initially high voltage level (close to upper voltage cutoff level) to low voltage level (close to the lower voltage cutoff level), when the cathode only includes a conversion chemistry material (e.g., FeF₃ and/or other types of conversion chemistry materials). However, and as shown in FIG. 3C, when the cathode also includes a low voltage intercalation material, the lower voltage cut-off is railed. In FIG. 3C, the battery voltage does not drop below the lower voltage cut-off because the intercalation material maintains a higher cell voltage that would be possible if only the conversion chemistry material was present.

Depending on the state of charge and the type of conversion material, the battery cell with conversion chemistry material may operate under two regimes. When the battery charge is substantially full, the battery cell operates in an intercalation (fast) regime. That is, the conversion chemistry material discharges with intercalation processes. During the intercalation regime, the cell voltage is relatively high and has enough headroom to provide the power and voltage needed at time 301B. At time 301B, the drop in voltage corresponding to electric vehicle acceleration at time 301A does not cause the cell voltage level to drop below the lower voltage cutoff, and the electric vehicle operates normally.

However, when the battery cell operates in the conversion regime (i.e., the conversion material is discharging or charging by way of a conversion chemistry reaction and not by way of an intercalation chemistry reaction) as shown in FIG. 3B between time 301B and 302B, the battery cell voltage is substantially constant, but is at a lower level, which can be close to lower voltage cutoff level. When the electric vehicle accelerates, during time 302A, the increased power demand may cause the cell voltage to drop below the lower voltage cutoff level, as shown in time 302B. When the voltage level of the battery cell falls below the lower voltage cutoff, the cell cannot deliver the required power. When the battery cell (or the battery pack made of a large of battery cells) is not above the lower voltage cutoff level, it cannot meet the power demand, and as a result, the electric vehicle cannot accelerate as needed.

When the cathode includes both intercalation and conversion chemistry materials, the operation of the electric vehicles is significantly improved, as demonstrated in FIG. 3C. The graph in FIG. 3C shows the cell voltage for a battery cathode having both intercalation chemistry materials (e.g., LTO) and conversion chemistry material (e.g., FeF₃). As explained above, other types of intercalation chemistry materials and conversion chemistry materials can be used as well. At time 301C, the cell voltage is well above the lower voltage cutoff level, and thus even when the acceleration at time 301A causes the cell voltage level to drop, the cell voltage level is still well above the lower voltage cutoff level. At time 302C, the cell, which primarily comprises (e.g., over 80% of total weight) conversion chemistry materials, is operating in the conversion regime. At time 302C, the cell voltage is close to the lower voltage cutoff level. The intercalation chemistry material, at time 302C, provides much needed power to when the electric vehicle operates at time 302A, thereby preventing the cell voltage to drop below the lower voltage cutoff at time 302C and allowing the electric vehicle to accelerate as needed. For example, the lower voltage cutoff level is about 1.5V. At around 1.5V, the intercalation chemistry material contributes to the power needed by the electric vehicle. Cell voltage is “railed” or otherwise stabilized at the voltage level attributed to the intercalation material, and the battery back as a whole can satisfy the power demand of the electric vehicle for acceleration. It is to be noted that when the electric vehicle accelerates, the increased power demand causes the cell voltage to drop. When the acceleration stops and power demands decreases, the conversion chemistry material can discharge and thereby recharge the intercalation chemistry material. As mentioned above, the intercalation material is specifically configured to provide operating headroom in situations such as time 302C, and only makes up a small portion of battery cell cathode. Thus, the intercalation material is recharged when possible, and the recharged intercalation material can provide supplemental power at a later time when needed.

FIG. 4 is a simplified diagram illustrating operation of a mixed material cathode at low temperature when the electric vehicle performs regenerative braking. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. FIG. 4A shows the power demand as a function of time for regenerative braking of a vehicle at low temperature (e.g., 0 Celsius). For example, the vehicle can be an electric vehicle or a hybrid vehicle. FIG. 4B shows voltage output, as function of time, for a battery cell whose cathode comprises a conversion chemistry material (e.g., FeF₃ or other types of conversion chemistry material). FIG. 4C shows voltage output, as a function of time, for a battery cell whose cathode comprises both conversion chemistry materials and intercalation chemistry materials (e.g., LTO or other types of intercalation materials).

As shown in FIG. 4A, power demand from the vehicle, under 0° C. isothermal condition, is substantially constant, except during time 401A and time 401B when the vehicle is braking. During time 401A and 401B, the power demand is low and negative, as the regenerative braking process generates power from the braking process, and the power from the regenerative braking process can be used to charge the battery. In FIG. 4B, the graph shows operation of a battery cell comprising a conversion chemistry material (e.g., FeF₃ or other types of conversion chemistry materials). The conversion-chemistry-only battery cell in FIG. 4B operates in two regimes: initially in the intercalation regime and then later in time, as the voltage drops, in the conversion regime. During the intercalation regime, the cell voltage starts relatively high and is close to the upper voltage cutoff level. For example, the upper voltage cutoff level may be around 4.2V. As vehicle operation drains the battery cell, the cell voltage drops, until the battery cell starts operating in the conversion region. During time 401B, which corresponds to time 401A of generative braking, the cell voltage goes up as the battery is recharged by the regenerative braking process. Since the cell voltage level at time 401B is relatively high and close to the upper voltage cutoff level, the recharging of the battery from the regenerative braking process spikes up the cell voltage to a level above the upper voltage cutoff level. While recharging of the battery cell is generally desirable, the battery cell cannot accept the recharging once the voltage is above the upper level cutoff. In addition to wasting the power from regenerative braking recharge, the power over the upper voltage cutoff level can lead to unsafe operating condition for the battery cell. When the battery cell operates in conversion regime, the voltage level is relatively low, cell voltage spike at time 402B does not pose the same type of problem as when the cell voltage is high and close to the high voltage cutoff.

FIG. 4C shows the benefit of a battery cell that includes both intercalation chemistry and conversion chemistry materials. For example, intercalation chemistry material include, but are not limited to LCO material, and the conversion chemistry material include, but are not limited to, FeF₃ material. Other materials are possible as well. At time 401C, which corresponds to time 401A, battery cell is recharged from the regenerative braking, but the cell voltage does not go over the upper voltage cutoff level (e.g., 4.2V). This is because when the voltage level goes above 4.2V, the intercalation chemistry material (e.g., LCO material) accepts the regenerative power. Voltage is “railed” at the upper voltage cutoff level, because the power over 4.2V is absorbed by the intercalation chemistry material; in other words, the intercalation chemistry material is charged at time 401C. Since the intercalation chemistry material absorbs the power when voltage is at or above the upper voltage cutoff level, the potentially unsafe operating condition of voltage over 4.2V is avoided at time 401C. The intercalation chemistry material can be partially charged during time 402C, but is it not necessarily so for the purposed of keeping voltage level below the upper voltage cutoff level.

Depending on the application, a cathode may include, in addition to a conversion chemistry material, two or more intercalation chemistry materials. The two intercalation chemistry materials have different operating voltages, which can widen the range of operating conditions. For example, the two intercalation chemistry materials include a first intercalation material that is characterized by a voltage plateau lower than that of the second intercalation material and the conversion chemistry material but above the system cutoff voltage. The second intercalation material is characterized by a voltage plateau higher than that of the first intercalation material and the conversion chemistry material but lower than the system cutoff voltage. In a specific embodiment, the first intercalation material includes Li₄Ti₅O_J or other lithium titanate, and its voltage plateau is about 1.5 V vs Li; the second intercalation material includes LiCoO₂ or other lithium cobalt oxide, and its voltage plateau is about 4 V vs Li. A cathode with two intercalation chemistry materials and a conversion chemistry material can therefore have an operating voltage range of about 1.5 to 4.2V.

As shown in the FIGS. 3-4 and described above, conversion chemistry materials, depending on voltage and/or state of charge, operate in both an intercalation regime and a conversion regime. It is to be understood that when operating in intercalation regime, the conversion chemistry material has a first voltage range, and when operating in the conversion regime, the conversion chemistry material has a second voltage range that is different from the first voltage range. For example, the conversion chemistry material CoF₃ has a voltage range of about 3-5V during intercalation regime, and a voltage range of about 1.6-2.4V during the conversion regime. As an example, iron fluoride is a conversion chemistry material that operates in both the intercalation regime and the conversion regime.

Li⁺+FeF₃+e⁻=LiFeF₃  (intercalation)

2Li⁺+LiFeF₃+2e⁻=3LiF+Fe  (conversion)

With iron fluoride, the intercalation reaction is typically at a voltage of about 2.7-4V, and the conversion reaction is typically at a voltage below 2.4V. Other types of conversion chemistry materials have their respective intercalation and conversion voltages, where the intercalation regime voltage range is higher than the conversion regime voltage range. According to certain embodiments set forth herein, intercalation chemistry materials that are mixed with conversion chemistry material operate at a higher voltage than the intercalation regime voltage range and/or a lower voltage than the conversion regime voltage range.

FIGS. 5A-E are simplified diagrams illustrating operating scenarios of cathode with mixed conversion and intercalation materials according to embodiments of the disclosure set forth herein. These diagrams merely provide an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. Conversion materials, during discharge, may be characterized by one or two voltage plateaus or levels. A voltage plateau is a region on a plot of voltage versus charge with a gradual slope during a low-rate (e.g. constant current rate of C/10 or slower) discharge. FIG. 5A illustrates a nonlimiting example voltage versus charge curve of a conversion material that has an intercalation voltage regime and a conversion voltage (lower) regime and a second material with an intercalation voltage between the two voltage regimes of the conversion material. FIG. 5B illustrates a nonlimiting example intercalation material with a voltage plateau below the conversion potential of the conversion material, an arrangement that may help in conditions of low temperature acceleration at low state of charge (SOC). FIG. 5C shows an intercalation material with a voltage plateau above the high voltage of the intercalation material, an arrangement that may help in conditions of low temperature regenerative breaking at high SOC. FIG. 5D shows two intercalation materials with voltage plateaus bracketing the conversion material conversion voltage. FIG. 5E shows two intercalation materials, one with a voltage plateau above the intercalation regime of the conversion material and another with a voltage plateau below the conversion plateau of the conversion material.

It is to be appreciated that there are many types of conversion chemistry and intercalation chemistry materials, and different materials have different operating conditions, such as operating temperature, operating voltage, and others. FIG. 6 is a table illustrating operating voltages of different metal materials in conversion reactions. Thermodynamic calculations and tables such as FIG. 6 may be used to determine approximate voltages of conversion materials, while experiments may be required to demonstrate the voltages empirically. FIG. 6 may therefore be used to design a hybrid intercalation/conversion positive electrode by selection of intercalation materials with the appropriate voltage plateaus.

FIG. 7 is a simplified diagram illustrating a battery cell according to an embodiment of the disclosure herein. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown in FIG. 7, the battery cell 700 includes current collectors 705 and 704, anode 703, electrolyte 702, and cathode 701. Cathode 701 includes three layers of materials: conversion material 701C, first intercalation material 701A, and second intercalation material 701B. In some examples, the first intercalation material 701A has a lower voltage plateau than the lower voltage of the conversion material and is positioned closer to the electrolyte 702 relative to the second intercalation material 701B and the conversion material 701C. The second conversion material 701B has a higher voltage plateau than the upper voltage of the conversion material, and is positioned between the first intercalation material 701A and the conversion material 701C. In various implementations, the first intercalation material 701A has a lower voltage and therefore would likely be subjected to higher current density than the second intercalation material 701B and the conversion material 701C, and therefore needs closer ionic access to the electrolyte 702.

FIG. 23 is a simplified diagram illustrating a battery cell according to an embodiment of the disclosure herein. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown in FIG. 23, the battery cell 2400 includes current collectors 2402 and 2407, negative electrode 2406, electrolyte 2405, and positive electrode 2401. Positive electrode 2401 includes two layers of materials: conversion material 2403 and intercalation material 2404. In some examples, the intercalation material 2404 has a lower voltage plateau than the lower voltage of the conversion material and is positioned closer to the electrolyte 2405 than the conversion material 2403. In some other examples, the intercalation material 2404 has a higher voltage plateau than the higher voltage of the conversion material and is positioned closer to the electrolyte 2405 than the conversion material 2403.

FIG. 8 shows an example cathode electrode suitable for use with the battery devices set forth herein. In FIG. 8, a current collector for a cathode has cathode active materials on two opposing sides of the current collector. These cathode active materials can include conversion chemistry materials, intercalation chemistry materials, both conversion chemistry materials and intercalation chemistry materials, more than one type of intercalation material, conversion chemistry materials and more than one type of intercalation material, or combinations of these options. A catholyte may also be included with these cathode active materials. In some examples, as described below, different types of conversion chemistry materials are used on each opposite side of the current collector. In some examples, the thickness of the cathode on one side of the current collector is not equal to the thickness of the cathode on the other side of the current collector, as shown in FIG. 8. In some examples, one side of the current collector has a thicker layer of cathode active materials than the layer of cathode active materials on the other side of the current collector.

FIG. 9 (presented as FIGS. 9A-9F) shows a list of intercalation materials with discharge voltages between about 1.3-2.5V that are suitable for use with the cathode active materials, e.g., conversion chemistry materials, also set forth herein. In some examples, the compositions set forth herein include at least one or more intercalation materials with discharge voltages between about 1.8-2.1V in combination with conversion chemistry materials, e.g., metal fluorides.

FIG. 10 (presented as FIGS. 10A-10F) shows a list of intercalation materials with discharge voltages between about 2.5-3.8V that are suitable for use with the cathode active materials, e.g., conversion chemistry materials, also set forth herein. In some examples, the compositions set forth herein include at least one or more intercalation materials with discharge voltages between about 2.5-3.8V in combination with conversion chemistry materials, e.g., metal fluorides, nickel fluorides.

In some examples, the compositions set forth herein include at least one or more intercalation materials with discharge voltages between about 1.8-2.1V in combination with at least one or more intercalation materials with discharge voltages between about 2.5-3.8V and in combination with conversion chemistry materials, e.g., metal fluorides, nickel fluorides, iron fluorides.

Example Combinations of Conversion Chemistry and Intercalation Chemistry Materials in Cathode

In some examples set forth herein, the hybrid electrodes include a conversion chemistry material, described in this application, in combination with at least one intercalation material that is an oxide or a phosphate or both. In some examples, these oxides or phosphates are selected from the materials listed in the table in FIG. 9 (presented in the form of multiple sheets labeled FIGS. 9A-9F). In some examples, these intercalation materials have discharge voltages between 1.3 and 2.5V. In some other examples, these intercalation materials have discharge voltages between 1.8 and 2.1V. In some of these examples, the conversion material combined with these intercalation materials is iron fluoride.

In some examples, these oxides or phosphates are selected from the materials listed in the table in FIG. 10. In some examples, these intercalation materials have discharge voltages between 2.5 and 3.0 V. In some of these examples, the conversion material combined with these intercalation materials is nickel fluoride. In some of these examples, the conversion material combined with these intercalation materials is iron fluoride. In some of these examples, the conversion material combined with these intercalation materials is a combination of nickel fluoride and iron fluoride (e.g., FeF₃).

In some examples, when the conversion chemistry material is nickel fluoride the combined intercalation chemistry materials have discharge voltages between 2.5 and 3.0 V.

In some examples, the hybrid electrode includes a metal fluoride as the conversion chemistry material (e.g., NiF₂, FeF₃, or combinations thereof) and a member selected from the group consisting of TiS₂, FeS, FeS₂, CuS, LTO (e.g., LiTiO₂, or Li_4-7Ti₅O₁₂, or Li₄Ti₅O₁₂ i.e., lithium titanate or LTO), and combinations thereof. In some of these examples, the metal fluoride is a member selected from the group consisting of FeF₃, CuF₂, NiF₂, and combinations thereof. In some of these examples, the metal fluoride is a member selected from the group consisting of iron fluoride, copper fluoride, nickel fluoride, and combinations thereof. In some of these examples, the metal fluoride is doped with Cu, Ni, Li₂O, a transition metal oxide, or combinations thereof. In some examples, the hybrid electrode includes FeF₃ and an intercalation material in FIGS. 9A-F, in FIGS. 10A-F, or intercalations materials selected from both FIGS. 9A-F and FIGS. 10A-F.

In some examples, the hybrid electrode includes FeF₃ and TiS₂. In some examples, the hybrid electrode includes FeF₃ and FeS. In some examples, the hybrid electrode includes FeF₃ and FeS₂. In some examples, the hybrid electrode includes FeF₃ and CuS. In some examples, the hybrid electrode includes FeF₃ and LTO (i.e., a lithium titanate). In some examples, the hybrid electrode includes FeF₃ and Li_0-1TiO₂. In some examples, the hybrid electrode includes FeF₃ and Li_0-1FeCuS₂.

In some of these examples, FeS has a discharge voltage at 1.6 V vs. Li. In some examples, FeS₂ has a discharge voltage at about 1.5 V-1.8 V vs. Li. In some examples, CuS has a discharge voltage at about 1.7-2.05 V vs. Li. In some examples, TiS₂ has a discharge voltage at 1.6-2.2 V vs. Li. In some examples, LTO has a discharge voltage at 1.5 V vs. Li.

In some of these examples, a catholyte is included with these cathode combinations of conversion chemistry materials and intercalation chemistry materials. In some examples, the catholyte is a lithium, phosphorus, and sulfur containing specie. In some examples, the catholyte comprises a lithium, phosphorus, and sulfur containing specie. In some examples, the catholyte is a lithium stuffed garnet. In some examples, the catholyte is a lithium stuffed garnet doped with alumina. In some examples, the catholyte is a lithium silicon sulfide. In some examples, the catholyte comprises a lithium silicon sulfide. In some examples, the catholyte comprises a lithium, phosphorus, tin, silicon sulfide. Suitable catholyte materials may be found in International PCT Patent Application No. PCT/US14/38283, entitled SOLID STATE CATHOLYTE OR ELECTROLYTE FOR BATTERY USING Li_AMP_BS_C (M═Si, Ge, AND/OR Sn), filed May 15, 2014, the entire contents of which are herein incorporated by reference for all purposes.

In some examples, the cathode includes FeF₃, a catholyte, and an intercalation material with a discharge voltage between 1.8 and 2.1 V vs. Li. In some examples, the cathode includes FeF₃, a catholyte, and an intercalation material with a discharge voltage of about 2.0 V vs. Li. In some examples, the cathode includes FeF₃, a catholyte, and an intercalation material with a discharge voltage of 2.0 V vs. Li. In some examples, the cathode includes FeF₃, a catholyte, and an intercalation material with a discharge voltage of about 1.3-2.5 V vs. Li. In some examples, the cathode includes FeF₃, a catholyte, and an intercalation material with a discharge voltage of about 1.8-2.1 V v. Li. In some examples, the cathode includes FeF₃, a catholyte, and an intercalation material selected from a member in the table in FIG. 9 or combinations of the members in the table in FIG. 9.

In some examples, the hybrid electrode includes NiF₂ and Li₀_FeO₂. In some examples, the hybrid electrode includes NiF₂ and Li_0-1 MnO₂. In some examples, the hybrid electrode includes NiF₂ and Li_1,33-2CuO₂. In some examples, the hybrid electrode includes NiF₂ and an intercalation material in FIG. 10.

Double-Side Coated Electrode

In some examples, the battery device set forth herein includes a double-side coated electrode with one side of the current collector foil coated with a thicker electrode and the other side coated with a thinner electrode. For example, FIG. 8 illustrates a non-limiting example of such a double-sided coated electrode. In some examples, the thicker electrode is a metal fluoride with a conversion plateau higher than the discharge voltage of the cathode active material of the thinner electrode.

In some examples, the combination of intercalation chemistry materials and conversion chemistry materials includes metal fluorides as the conversion chemistry material. In some examples, both sides of the double-side coated electrode include conversion chemistry materials and intercalation chemistry materials. In some examples, both sides of the double-side coated electrode include conversion chemistry materials and intercalation chemistry materials, but each side of the double-side coated electrode has a different type of conversion chemistry material. In some of these examples, one side has a metal fluoride, and the other side has a doped metal fluoride. In some examples, both sides of the double-side coated electrode include conversion chemistry materials and intercalation chemistry materials, but each side of the double-side coated electrode has a different amount of conversion chemistry material.

In some examples, both sides of the double-side coated electrode include conversion chemistry materials and intercalation chemistry materials, but each side of the double-side coated electrode has a different type of intercalation chemistry material. In some examples, both sides of the double-side coated electrode include conversion chemistry materials and intercalation chemistry materials, but each side of the double-side coated electrode has a different amount of intercalation chemistry material.

In some examples, both sides of the double-side coated electrode include conversion chemistry materials and intercalation chemistry materials, but each side of the double-side coated electrode has a different type of conversion chemistry material and of intercalation chemistry material. In some examples, both sides of the double-side coated electrode include conversion chemistry materials and intercalation chemistry materials, but each side of the double-side coated electrode has a different amount of each type of conversion chemistry material and intercalation chemistry materials.

In yet other examples, one side of the double-side coated electrode includes a conversion chemistry material and the other side of the double-side coated electrode includes an intercalation chemistry material.

In some examples, the thicker electrode side includes a doped conversion material that has a higher, for example, 50-200 mV higher, discharge conversion plateau than the thinner electrode. This architecture surprisingly provides a driving force for “recharging” the thinner electrode after it is depleted in a pulse or low temperature power event.

In some examples, one or both sides of the double-side coated cathode is graded. In some examples, one or both sides of the double-side coated cathode is a two-layer single electrode.

In some examples, one or both sides of the double-side coated cathode is a two-layer single electrode where the layer in immediate contact with the current collector includes a “doped” conversion material with a higher voltage conversion plateau than the other cathode active material. In this architecture, the undoped conversion material serves as the “power” layer. In some examples of this architecture, the open circuit voltage difference between these layers provides an enthalpic driving force for one layer of the cathode to recharge the other layer of the cathode.

Nanodimensioned Conversion Chemistry and Intercalation Chemistry Materials in Cathode

In some examples set forth herein, either the conversion chemistry material or the intercalation chemistry material, or both, are nanodimensioned. In some examples, the conversion chemistry material is nanodimensioned and described as particles or grains of conversion chemistry material wherein the particles or grains have a d₅₀ diameter of about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 nm. In some examples, the intercalation chemistry material is nanodimensioned and described as particles or grains of intercalation chemistry material wherein the particles have a d₅₀ diameter of about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 nm. In some examples, these nanodimensioned particles of conversion chemistry materials and intercalation chemistry materials are intimately mixed together.

As used herein, d₅₀ refers to the median diameter or the median size, in a distribution of sizes, measured by microscopy techniques, such as, but not limited to, scanning electron microscopy. As used herein, d₅₀ includes the characteristic dimension at which 50% of the particles are smaller than the recited size.

As used herein, d₅₀ is measured by light scattering, for example, on a Horiba LA-950 V2 particle size analyze using acetonitrile as a solvent and one-minute sonication before measurement.

In some examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 1 nm. In some other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 2 nm. In other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 3 nm. In still other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 4 nm. In yet other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 5 nm. In some examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 6 nm. In some other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 7 nm. In other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 8 nm. In still other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 9 nm. In yet other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 10 nm. In some examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 11 nm. In some other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 12 nm. In other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 13 nm. In still other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 14 nm. In yet other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 15 nm. In some examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 16 nm. In some other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 17 nm. In other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 18 nm. In still other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 19 nm. In yet other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 20 nm. In some examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 21 nm. In some other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 22 nm. In other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 23 nm. In still other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 24 nm. In yet other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 25 nm. In some examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 26 nm. In some other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 27 nm. In other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 28 nm. In still other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 29 nm. In yet other examples, the grains of conversion chemistry materials that are mixed with intercalation chemistry materials have a d₅₀ of 30 nm.

Amounts of Conversion Chemistry and Intercalation Chemistry Materials in Cathode

In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is less than 30% w/w (by weight). In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 29.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 29.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 28.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 28.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 27.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 27.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 26.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 26.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 25.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 25.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 24.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 24.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 23.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 23.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 22.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 22.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 21.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 21.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 20.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 19.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 18.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 18.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 17.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 17.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 16.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 16.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 15.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 15.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 15.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 15.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 14.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 14.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 13.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 13.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 12.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 12.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 11.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 11.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 10.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 9.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 9.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 8.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 8.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 7.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 7.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 6.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 6.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 6.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 5.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 4.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 4.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 4.0% w/w. In yet other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 3.5% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 3.0% w/w. In some examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 25% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 2.0% w/w. In certain examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 1.5% w/w. In other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 1.0% w/w. In still other examples, the amount of intercalation chemistry material that is mixed with the conversion chemistry material is present in the cathode at an amount of 0.5% w/w.

In some examples, the conversion material is FeF₃ or NiF₂ and the intercalation material is present in the cathode at an amount of 10% w/w. In some examples, the conversion material is FeF₃ or NiF₂ and the intercalation material is present in the cathode at an amount of 5% w/w.

It is to be appreciated that embodiments of the disclosure set forth herein provide numerous advantages over conventional battery systems and methods. Among other things, with mixed intercalation and conversion chemistry materials, the cathode regions of battery cells can provide both high energy density and operating flexibility. The relatively small amount of the intercalation chemistry material at the cathode can provide additional degrees of flexibility in battery design to meet requirements of battery operation at low temperature or near its voltage limits, without adding too much weight. For example, during regenerative braking process of operating an electric vehicle, the intercalation chemistry material absorbs electrical power when voltage is too high for the conversion chemistry material. As another example, when conversion chemistry material is operating under conversion regime and the cell voltage is low, the intercalation chemistry material can satisfy peak power demand. The conversion chemistry material, which offers higher energy density and capacity than the intercalation chemistry material, provides energy at a steady voltage for other operation of electric motors. There are other benefits as well.

EXAMPLES

Example 1—Positive Electrode Preparation

Positive electrodes were prepared by mixing and milling either crystalline FeF₃ or an 80:20 w/w mixture of crystalline iron trifluoride (i.e.,FeF₃) and lithium titanate (LTO) with carbon (C65 Conductive Carbon Black) and an Ethylene Propylene Rubber binder (EPR). These positive electrodes were disposed onto a liquid electrolyte including celgard membrane which was disposed on and contacting a Li-metal anode. The celgard separator contained the liquid electrolyte and physically separated the positive and negative electrodes. The liquid electrolyte included ethylene carbonate (EC) dimethylcarbonate (DMC) solvents in a 50:50 v/v (EC:DMC) ratio with 1M LiPF₆ salt. In some examples, the electrochemical cells included only FeF₃ as the positive electrode active material. In some other examples, the electrochemical cells included both FeF₃ and LTO in an 80:20 w/w ratio as the positive electrode active material.

Example 2—Electrochemical Testing of Hybrid Positive Electrodes with Comparison to Positive Electrodes Having Conversion Chemistry Active Materials

FIG. 11 shows a high rate discharge initially after assembling the electrochemical cell (i.e., 0^th discharge). The discharge was run at C/10 rate and at 50° C. The plateau at 1.6V in the LTO-including sample shows that the positive electrode with both FeF₃ and LTO took a longer time during discharge to reach the 1.5V floor. This example demonstrates that LTO, with a lower operating voltage above the lowest conversion voltage for FeF₃ “railed,” or prevented, the electrochemical cell from dropping to 1.5V as soon as it would have in the absence of LTO (i.e., in the electrochemical cell having only FeF₃).

FIG. 12 shows the subsequent charging of the electrochemical cells used in the experiment to generate the data in FIG. 1.1. The initial plateau at 1.6V in the LTO-including sample shows that the positive electrode with both FeF₃ and LTO begins the charging cycle at a higher voltage than the positive electrode with only FeF₃ active material. This example also demonstrates that LTO, which has a lower operating voltage which is above the lowest conversion voltage for FeF₃, “railed” the electrochemical cell from dropping to 1.5V as soon as it would have in the absence of LTO (i.e., in the electrochemical cell having only FeF₃).

Example 3—Electrochemical Testing of Hybrid Positive Electrodes with Comparison to Positive Electrodes Having Conversion Chemistry Active Materials

Electrochemical cells were prepared according to Example 1. These electrochemical cells were analyzed at 50° C. using the following pulse cycle: An C/10 rate continuous discharge pulse, followed by a rest to allow the cell voltage to equilibrate, and 1 minute current pulses of C/5, C13, and C/2, each with a five (5) minute rest period in between the discharge pulse. The cell Voltage (V v. Li) as a function of Run Time (s) was observed and recorded as FIGS. 13-18. The control samples only included FeF₃ as the positive electrode active material. The LTO samples included both FeF₃ and LTO (lithium titanate) in an 80:20 w/w ratio.

FIG. 13 shows the discharge voltage versus time near the end of a discharge for two representative control cells with 100% conversion chemistry, FeF₃, cathodes compared to two representative cells with a hybrid cathode: 80 wt % conversion chemistry, FeF₃, and 20 weight % intercalation chemistry, LTO. The intercalation material has a discharge voltage between 1.55-1.64V. FIGS. 13 and 14 show that the hybrid cathode has shallower voltage spikes during the current pulses and therefore hits the voltage floor later than the cathode having only conversion chemistry active materials. FIGS. 13 and 13 show that the hybrid cathode was observed to have nearly 10% more capacity and less degradation of the electrolyte, and thus a longer battery cycle life.

FIG. 14 shows the electrochemical test using the same conditions above but magnified (i.e., zoomed in) to show the last discharge and only showing one representative cell from each batch for clarity. Of particular note is the relative voltage spike near 39500 seconds indicated by the left arrow, and the shallow voltage of discharge indicated by the second arrow, and the following discharge. This example demonstrates that LTO, with a discharge voltage above the lowest conversion voltage for FeF₃ “railed,” or prevented, the electrochemical cell from dropping to the lower voltage than the cathode having only FeF₃ achieved.

Example 4—Electrochemical Testing of Hybrid Positive Electrodes with Comparison to Positive Electrodes Having Conversion Chemistry Active Materials

FIG. 15 shows the electrochemical test using the same conditions above. In this example, the data is analyzed to extract the area-specific resistance (ASR_dc) versus pulse cycle throughout the discharge. As shown in FIG. 15, the cathode including LTO and FeF₃ was observed to have a lower ASR throughout the discharge, particularly at the last pulse.

FIGS. 16-18 show additional electrochemical results using the same conditions above but magnified (i.e., zoomed in) to show the last discharge and only showing one representative cell from each batch for clarity. This example demonstrates that LTO, with a discharge voltage above the lowest conversion voltage for FeF₃ “railed,” or prevented, the electrochemical cell from dropping to the lower voltage than the cathode having only FeF₃ achieved.

Example 5—Hybrid Electrode Calculations for Hybrid Positive Electrodes with Comparison to Positive Electrodes Having Either Only Conversion Chemistry Active Materials or Only Intercalation Chemistry Active Materials

To simulate how mixing cathode materials affects the voltage response, an equivalent circuit model of the system was constructed. There model included linear equations useful for calculating a positive electrode voltage and three types of components including: 1) Resistive elements which were used to model ohmic resistance to either ionic or electronic transport; Capacity elements which represented materials which store charge electrochemically and have both an open circuit voltage and a capacity, and Resistor/capacitor pairs which model charge-transfer effects where exchange current is limited by reaction kinetics. The components which comprised the conversion and intercalation materials were arranged in discrete layers to represent the hybrid chemistry electrodes. The characteristics of these components may vary with temperature, state of charge, direction of load current, magnitude of load current, and various other factors. The characteristics of these components may be set to simulate any of the conversion or intercalation chemistries mentioned in this document. To simulate the voltage response of the battery, a controlled current load is attached to the terminals of the model. Using the known load current, the cell voltage may be determined using circuit analysis techniques.

MATERIALS—In this example, a total of the three cathode layers were used. There are two layers of conversion material (FeF₃) and one layer of intercalation material (LTO or LCO). The layer of intercalation material was placed closest to the anode of the battery. It is to be appreciated that the number and type of materials selected and their respective capacity may be adjusted as needed to simulate the desired combination.

RESULTS—The power demand profile shown in FIG. 19 shows the controlled load stimulus which generates the voltage response in FIG. 20. FIG. 20 shows three sets of simulation results. The first shows the voltage response to the power demand from a battery with only conversion chemistry active materials in the positive electrode. The second shows the voltage response to the power demand from a battery with both intercalation chemistry active materials mixed with conversion chemistry active materials, in a 95:5 w/w ratio, in the positive electrode. The third shows the voltage response to the power demand from a battery with only intercalation material in the positive electrode.

This Example shows, in FIG. 20, that the voltage of the mixed chemistry battery does not fall below the lower voltage threshold during a high power demand event at low state of charge.

The power demand profile shown in FIG. 21 shows the controlled load stimulus which generates the voltage response in FIG. 22. FIG. 22 shows three sets of simulation results. The first shows the voltage response to the power demand from a battery with only conversion chemistry active materials in the positive electrode. The second shows the voltage response to the power demand from a battery with both intercalation chemistry active materials mixed with conversion chemistry active materials, in a 90:10 w/w ratio, in the positive electrode. The third shows the voltage response to the power demand from a battery with only intercalation material in the positive electrode.

This Example shows, in FIG. 222, that the voltage of the mixed chemistry battery does not exceed the upper voltage cutoff during a high power regenerative brake event at high state of charge.

While the above is a full description of the specific embodiments, various modifications, alternative constructions and equivalents may be used. Therefore, the above description and illustrations should not be taken as limiting the scope of the present invention which is defined by the appended claims.

Claims

1. An electrochemical device comprising:

an anode region;

an electrolyte region; and

a cathode region comprising an intercalation chemistry active material and a conversion chemistry active material,

wherein the electrolyte region is positioned between the anode region and the cathode region,

wherein the conversion chemistry active material is present in the cathode region at a weight fraction greater than about 70 w/w % of the active material in the cathode region;

wherein the intercalation chemistry active material is present in the cathode region at a weight fraction less than about 30 w/w % of the active material in the cathode active region,

wherein the intercalation chemistry active material and the conversion chemistry active material are homogenously mixed in the cathode region.

2-6. (canceled)

2. The device of claim 1 wherein the electrolyte region comprises lithium silicon sulfide.

3. The device of claim 1 wherein the electrolyte region comprises a lithium, phosphorus, tin, and/or silicon sulfide.

4. The device of claim 1 wherein the electrolyte region comprises a garnet electrolyte or a sulfide electrolyte.

5. The device of claim 1 wherein the conversion chemistry active material is selected from the group consisting of FeF2, NiF2, FeOxF3-2x, FeF3, MnF3, CoF3, CuF2 materials and alloys or combinations thereof.

6. The device of claim 1 wherein the intercalation chemistry active material comprises LiFePO4, LixTiyOz, LiNixMn2-xO4, LiCoO2, Li(NiCoMn)O2, and/or Li(NiCoAl)O2 materials.

7. The device of claim 1 wherein the intercalation chemistry active material is selected from Li(NiCoMn)O2, Li(NiCoAl)O2, and Nickel Cobalt Aluminum Oxides (NCA), wherein the intercalation chemistry active material has a discharge voltage between 1.3V and 2.5V.

13. (canceled)

8. The device of claim 1 wherein the conversion chemistry active material is characterized by a first upper voltage level and the intercalation chemistry active material is characterized by a second upper voltage level, the first upper voltage level being lower than the second upper voltage level.

9. (canceled)

10. The device of claim 1 wherein the conversion chemistry active material is characterized by a conversion voltage which is above the intercalation voltage of the intercalation chemistry active material.

11.-18. (canceled)

12. The device of claim 1 wherein the cathode region comprises a conversion material and at least two different types of intercalation chemistry active materials.

13. (canceled)

14. (canceled)

15. (canceled)

16. The system of claim 14 wherein the BMS is configured to charge the battery pack by pulse charges, wherein the intercalation chemistry active material comprises LiFePO4, LixTiyOz, LiNixMn2-xO4, LiCoO2, Li(NiCoMn)O2, and/or Li(NiCoAl)O2 materials

24. The system of claim 14 wherein the intercalation chemistry active material is selected from Li(NiCoMn)O2 and/or Li(NiCoAl)O2 materials wherein the intercalation chemistry active material has a discharge voltage between 1.3V and 2.5V.

17.-31. (canceled)

18. An electrochemical device comprising:

an anode region;

an electrolyte region; and

a cathode region comprising one or more intercalation chemistry active materials and a conversion chemistry active material, wherein the intercalation chemistry active material and the conversion chemistry active material are homogenously mixed in the cathode region;

wherein the weight ratio of the conversion chemistry active material to the one or more intercalation chemistry active materials is between 70:30 and 99:1,

wherein the intercalation chemistry active material comprises LiFePO4, LixTiyOz, LiNixMn2-xO4, LiCoO2, Li(NiCoMn)O2, and/or Li(NiCoAl)O2 materials.

19. The electrochemical device of claim 32, wherein the one or more intercalation chemistry active materials is material is selected from Li(NiCoMn)O2 and/or Li(NiCoAl)O2 materials, wherein the intercalation chemistry active material has a discharge voltage between 1.3V and 2.5V.

20. (canceled)

21.-59. (canceled)

60. The device of claim 1, wherein the conversion chemistry active material particles when charged comprise FeF3; and wherein the conversion chemistry active material particles when discharged comprise LiF and a nanodimensioned Fe.

61. The device of claim 1, wherein the intercalation chemistry active material particles include a member selected from the group consisting of LiTiO2, Li4.7Ti5O12, Li4Ti5O12, and combinations thereof.

62. The device of claim 1, wherein the intercalation chemistry active material particles include a member selected from the group consisting of Li3-4TiFe3O8, Li2-4TiV3O5, Li3-5TiMn3O6, Li1-3Ti2V5O12, Li0-1La4Ti3O12, Li1-5Ti2V3O15, Li0.67-2TiVO4, Li1-2TiVO5, Li7-9Ti1.2NbO30, Li0-1TiP2O7, Li4-5Ti3O5, Li1-2TiVO4, Li0-1TiO2, Li4-7Ti11O24, Li1-4Ti3VO3, Li0-1TiO2, Li0.75-1TiO2, Li1-2Ti2VO4, Li7-9Ti7Nb5O30, Li2-3TiV2O6, Li0-5Ti4VO8, Li0-1TiO2, Li0-1TiP2O7, and combinations thereof.

63. The device of claim 1, wherein the conversion chemistry active material is present in the cathode region at a weight fraction greater than about 80 w/w % of the active material in the cathode region, wherein the intercalation chemistry active material is present in the cathode region at a weight fraction less than about 20 w/w % of the active material in the cathode active region.

64. The device of claim 1, wherein the conversion chemistry active material is present in the cathode region at a weight fraction greater than about 85 w/w % of the active material in the cathode region, wherein the intercalation chemistry active material is present in the cathode region at a weight fraction less than about 15 w/w % of the active material in the cathode active region.

65. The device of claim 1, wherein the cathode includes a binder, wherein the binder is at least one of polypropylene, ethylene propylene rubber, ethylene pentene copolymer, polyisobutylene, styrene butadiene rubber, polyolefins, polyethylene-co-poly-1-octene, PE-co-poly(methylene cyclopentane, sterioblock polypropylenes, polypropylene polymethylpentene copolymer, polyethylene oxide, silicone, or combinations thereof.