# US 2018/0323474 A1 · Rolled Alkali Metal Batteries and Production Process > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2018/0323474 A1 - Document ID: US20180323474A1 - Status: Published application - Kind: A1 - Application number: 15/589,629 - Filed: 2017-05-08 - Published: 2018-11-08 - Earliest claimed: 2017-05-08 - Assignees: Nanotek Instruments, Inc. - Applicants: Nanotek Instruments, Inc. - Inventors: Chueh Liu; Aruna Zhamu; Bor Z. Jang - Web page: https://patentgrep.com/patent/US20180323474A1 ## CPC - H01M 10/054: Accumulators with insertion or intercalation of metals other than lithium, e.g. with magnesium or aluminium - H01M 4/0404: {by coating on electrode collectors} - H01M 4/13: Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof - H01M 4/139: Processes of manufacture - H01M 4/48: of inorganic oxides or hydroxides - H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries - H01M 10/058: Construction or manufacture - H01M 4/505: of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy - H01M 4/525: of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy - H01M 4/5825: {Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines} - H01M 4/587: for inserting or intercalating light metals - H01M 10/0568: characterised by the solutes - H01M 10/0569: characterised by the solvents - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract Provided is a rolled alkali metal battery wherein the alkali metal is selected from Li, Na, K, or a combination thereof. The battery comprises an anode, a cathode, an alkali metal ion-conducting separator electronically separating the anode and the cathode, and an alkali metal ion-containing electrolyte in ionic contact with the anode and the cathode, wherein the anode contains a wound roll of an anode active material having an anode roll length, an anode roll width, and an anode roll thickness and/or the cathode contains a wound roll of a cathode active material having a cathode roll length, a cathode roll width, and a cathode roll thickness and wherein the anode roll width and/or the cathode roll width direction is substantially perpendicular to the separator plane. ## Claims ### Claim 1 A rolled alkali metal battery wherein said alkali metal is selected from Li, Na, K, or a combination thereof; said battery comprising an anode, a cathode, an alkali metal ion-conducting separator electronically separating said anode and said cathode, and an alkali metal ion-containing electrolyte in ionic contact with said anode and said cathode, wherein said anode contains a wound roll of an anode active material having an anode roll length, an anode roll width, and an anode roll thickness and/or said cathode contains a wound roll of a cathode active material having a cathode roll length, a cathode roll width, and a cathode roll thickness and wherein said anode roll width and/or said cathode roll width is substantially perpendicular to said separator. ### Claim 2 (depends on 1) The rolled alkali metal battery of claim 1, further containing an anode tab connected to or integral with said anode and a cathode tab connected to or integral with said cathode. ### Claim 3 (depends on 1) The rolled alkali metal battery of claim 1, further comprising a casing that encloses said anode, said cathode, said separator, and said electrolyte therein to form a sealed battery. ### Claim 4 (depends on 1) The rolled alkali metal battery of claim 1, wherein said wound roll of an anode active material contains (a) a layer of supporting solid substrate having two primary surfaces wherein either one or both of said primary surfaces are coated with said anode active material, an optional conductive additive, and an optional binder or (b) a layer of supporting porous substrate having pores that are impregnated with said anode active material, an optional conductive additive, and an optional binder. ### Claim 5 (depends on 1) The rolled alkali metal battery of claim 1, wherein said wound roll of a cathode active material contains (a) a layer of supporting solid substrate having two primary surfaces wherein either one or both of said primary surfaces are coated with said cathode active material, an optional conductive additive, and an optional binder or (b) a layer of supporting porous substrate having pores that are impregnated with said cathode active material, an optional conductive additive, and an optional binder. ### Claim 6 (depends on 1) The rolled alkali metal battery of claim 1, wherein said alkali metal battery is a lithium metal battery, sodium metal battery, or potassium metal battery and the anode contains a foil or coating of Li, Na, or K metal supported by or coated on a solid or porous supporting substrate. ### Claim 7 (depends on 1) The rolled alkali metal battery of claim 1, wherein said alkali metal battery is a lithium-ion battery and said anode active material is selected from the group consisting of: (a) particles of natural graphite, artificial graphite, meso-carbon microbeads (MCMB), needle coke, carbon particles, carbon fibers, carbon nanotubes, and carbon nano-fibers; (b) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), nickel (Ni), cobalt (Co), manganese (Mn), titanium (Ti), iron (Fe), and cadmium (Cd); (c) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, or Cd with other elements, wherein said alloys or compounds are stoichiometric or non-stoichiometric; (d) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ni, Co, Ti, Mn, or Cd, and their mixtures or composites; (e) pre-lithiated versions thereof; (f) pre-lithiated graphene sheets; and combinations thereof. ### Claim 8 (depends on 1) The rolled alkali metal battery of claim 1, wherein said alkali metal battery is a sodium-ion battery and said anode active material contains an alkali intercalation compound selected from petroleum coke, carbon black, amorphous carbon, activated carbon, hard carbon, soft carbon, templated carbon, hollow carbon nanowires, hollow carbon sphere, titanates, NaTi2(PO4)3, Na2Ti3O7, Na2C8H4O4, Na2TP, NaxTiO2 (x=0.2 to 1.0), Na2C8H4O4, carboxylate based materials, C8H4Na2O4, C8H6O4, C8H5NaO4, C8Na2F4O4, C10H2Na4O8, C14H4O6, C14H4Na4O8, or a combination thereof. ### Claim 9 (depends on 1) The rolled alkali metal battery of claim 1, wherein the alkali metal battery is a sodium-ion battery and said anode active material contains an alkali intercalation compound selected from the following groups of materials: (a) sodium- or potassium-doped silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), cobalt (Co), nickel (Ni), manganese (Mn), cadmium (Cd), and mixtures thereof; (b) sodium- or potassium-containing alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Co, Ni, Mn, Cd, and their mixtures; (c) sodium- or potassium-containing oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides, or antimonides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ti, Co, Ni, Mn, Cd, and mixtures or composites thereof, (d) sodium or potassium salts; and (e) graphene sheets pre-loaded with sodium or potassium. ### Claim 10 (depends on 1) The rolled alkali metal battery of claim 1, wherein said cathode active material contains a lithium intercalation compound or lithium absorbing compound selected from the group consisting of lithium cobalt oxide, doped lithium cobalt oxide, lithium nickel oxide, doped lithium nickel oxide, lithium manganese oxide, doped lithium manganese oxide, lithium vanadium oxide, doped lithium vanadium oxide, lithium mixed-metal oxides, lithium iron phosphate, lithium vanadium phosphate, lithium manganese phosphate, lithium mixed-metal phosphates, metal sulfides, metal fluoride, metal chloride, and combinations thereof. ### Claim 11 (depends on 1) The rolled alkali metal battery of claim 1, wherein said cathode active material contains a sodium intercalation compound or a potassium intercalation compound selected from NaFePO4, Na(1-x)KxPO4, KFePO4, Na0.7FePO4, Na1.5VOPO4F0.5, Na3V2(PO4)3, Na3V2(PO4)2F3, Na2FePO4F, NaFeF3, NaVPO4F, KVPO4F, Na3V2(PO4)2F3, Na1.5VOPO4F0.5, Na3V2(PO4)3, NaV6O15, NaxVO2, Na0.33V2O5, NaxCoO2, Na2/3[Ni1/3Mn2/3]O2, Nax(Fe1/2Mn1/2)O2, NaxMnO2, λ-MnO2, NaxK(1-x)MnO2, Na0.44MnO2, Na0.44MnO2/C, Na4Mn9O18, NaFe2Mn(PO4)3, Na2Ti3O7, Ni1/3Mn1/3Co1/3O2, Cu0.56Ni0.44HCF, NiHCF, NaxMnO2, NaCrO2, KCrO2, Na3Ti2(PO4)3, NiCo2O4, Ni3S2/FeS2, Sb2O4, Na4Fe(CN)6/C, NaV1-xCrxPO4F, SezSy, y/z=0.01 to 100, Se, sodium polysulfide, sulfur, Alluaudites, or a combination thereof, wherein x is from 0.1 to 1.0. ### Claim 12 (depends on 1) The rolled alkali metal battery of claim 1, wherein said electrolyte contains a lithium salt or sodium salt dissolved in a liquid solvent and/or a polymer and wherein said liquid solvent is water, an organic solvent, an ionic liquid, or a mixture of an organic solvent and an ionic liquid. ### Claim 13 (depends on 1) The rolled alkali metal battery of claim 1, wherein said roll of anode active material has a width no less than 500 μm, said anode active material has a mass loading no less than 25 mg/cm2 and/or occupies at least 25% by weight or by volume of the entire battery cell, and/or the cathode active material has a mass loading no less than 20 mg/cm2 for an organic or polymer material or no less than 40 mg/cm2 for an inorganic and non-polymer material in said cathode and/or occupies at least 40% by weight or by volume of the entire battery cell. ### Claim 14 (depends on 1) The rolled alkali metal battery of claim 1, wherein said roll of anode active material has a width no less than 1000 μm or 1 mm, and/or said anode active material has a mass loading no less than 30 mg/cm2 and/or occupies at least 30% by weight or by volume of the entire battery cell, and/or the cathode active material has a mass loading no less than 25 mg/cm2 for an organic or polymer material or no less than 50 mg/cm2 for an inorganic and non-polymer material in said cathode and/or occupies at least 50% by weight or by volume of the entire battery cell. ### Claim 15 (depends on 1) The rolled alkali metal battery of claim 1, wherein said roll of anode active material has a width no less than 5 mm, and/or said anode active material has a mass loading no less than 35 mg/cm2 and/or occupies at least 35% by weight or by volume of the entire battery cell, and/or the cathode active material has a mass loading no less than 30 mg/cm2 for an organic or polymer material or no less than 55 mg/cm2 for an inorganic and non-polymer material in said cathode and/or occupies at least 55% by weight or by volume of the entire battery cell. ### Claim 16 (depends on 4) The rolled alkali metal battery of claim 4, wherein said layer of supporting porous substrate contains an electrically conductive porous layer selected from metal foam, metal web or screen, perforated metal sheet-based structure, metal fiber mat, metal nanowire mat, conductive polymer nano-fiber mat, conductive polymer foam, conductive polymer-coated fiber foam, carbon foam, graphite foam, carbon aerogel, carbon xerogel, graphene foam, graphene oxide foam, reduced graphene oxide foam, carbon fiber foam, graphite fiber foam, exfoliated graphite foam, or a combination thereof. ### Claim 17 (depends on 5) The rolled alkali metal battery of claim 5, wherein said layer of supporting porous substrate contains an electrically conductive porous layer selected from metal foam, metal web or screen, perforated metal sheet-based structure, metal fiber mat, metal nanowire mat, conductive polymer nano-fiber mat, conductive polymer foam, conductive polymer-coated fiber foam, carbon foam, graphite foam, carbon aerogel, carbon xerogel, graphene foam, graphene oxide foam, reduced graphene oxide foam, carbon fiber foam, graphite fiber foam, exfoliated graphite foam, or a combination thereof. ### Claim 18 (depends on 7) The rolled alkali metal battery of claim 7, wherein said pre-lithiated graphene sheets are selected from pre-lithiated versions of pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, boron-doped graphene, nitrogen-doped graphene, chemically functionalized graphene, a physically or chemically activated or etched version thereof, or a combination thereof. ### Claim 19 (depends on 1) The rolled alkali metal battery of claim 1, wherein said cathode active material comprises an alkali metal intercalation compound or alkali metal-absorbing compound selected from an inorganic material, an organic or polymeric material, a metal oxide/phosphate/sulfide, or a combination thereof. ### Claim 20 (depends on 19) The rolled alkali metal battery of claim 19, wherein said metal oxide/phosphate/sulfide is selected from a lithium cobalt oxide, lithium nickel oxide, lithium manganese oxide, lithium vanadium oxide, lithium-mixed metal oxide, lithium iron phosphate, lithium manganese phosphate, lithium vanadium phosphate, lithium mixed metal phosphate, transition metal sulfide, transition metal fluoride, transition metal chloride, or a combination thereof. ### Claim 21 (depends on 19) The rolled alkali metal battery of claim 19, wherein said inorganic material is selected from sulfur, sulfur compound, lithium polysulfide, transition metal dichalcogenide, a transition metal trichalcogenide, or a combination thereof. ### Claim 22 (depends on 19) The rolled alkali metal battery of claim 19, wherein said inorganic material is selected from TiS2, TaS2, MoS2, NbSe3, MnO2, COO2, an iron oxide, a vanadium oxide, or a combination thereof. ### Claim 23 (depends on 19) The rolled alkali metal battery of claim 19, wherein said metal oxide/phosphate/sulfide contains a vanadium oxide selected from the group consisting of VO2, LixVO2, V2O5, LixV2O5, V3O8, LixV3O8, LixV3O7, V4O9, LixV4O9, V6O13, LixV6O13, their doped versions, their derivatives, and combinations thereof, wherein 0.1