# US 2020/0395584 A1 · Catholyte management for a solid-state separator

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- Number: US 2020/0395584 A1
- Document ID: US20200395584A1
- Status: Published application
- Kind: A1
- Application number: 16/766,214
- Filed: 2018-11-28
- Published: 2020-12-17
- Earliest claimed: 2017-11-28
- Assignees: QuantumScape Corporation
- Applicants: Quantumscape Corporation
- Inventors: William H. GARDNER; Joseph SALVI
- Web page: https://patentgrep.com/patent/US20200395584A1

## CPC

- H01M 4/382: {Lithium (H01M4/405 takes precedence)}
- H01M 4/48: of inorganic oxides or hydroxides
- H01M 4/64: Carriers or collectors
- H01M 10/0565: Polymeric materials, e.g. gel-type or solid-type
- H01M 50/434: Ceramics
- H01M 50/497: Ionic conductivity
- H01M 2004/027: {Negative electrodes}
- H01M 2004/028: {Positive electrodes}
- H01M 2300/0068: inorganic
- H01M 2300/0085: Immobilising or gelification of electrolyte
- Y02E 60/10: Energy storage using batteries
- 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

## Abstract

Provided herein are electrochemical cells that include a seal impermeable to a liquid electrolyte and that is bonded to a solid-state Li ion-conducting electrolyte in a manner that effectively isolates and protects a Li metal negative electrode from exposure to either, or both, a liquid electrolyte or a gel electrolyte used as a catholyte in the positive electrode. Some of the electrochemical cells include a series of electrochemical stacks, which may be stacked in a variety of configurations including configurations that share a Li metal negative electrode.

## Claims

### Claim 1

An electrochemical stack, comprising a solid-state electrolyte;
a positive electrode comprising a liquid electrolyte or a gel electrolyte;
a positive electrode current collector; and
a seal impermeable to the liquid electrolyte or the gel electrolyte that bonds to the positive electrode current collector and to the solid-state electrolyte.

### Claim 2 (depends on 1)

The electrochemical stack of claim 1, wherein the seal contains the liquid electrolyte or the gel electrolyte in the positive electrode.

### Claim 3 (depends on 1, 2)

The electrochemical stack of claim 1 or 2, wherein the solid-state electrolyte is impermeable to the liquid electrolyte or the gel electrolyte.

### Claim 4 (depends on 1, 2, 3)

The electrochemical stack of any one of claims 1-3, wherein the solid-state electrolyte has tapered edges.

### Claim 5 (depends on 1, 2, 3, 4)

An electrochemical cell comprising at least one or more electrochemical stacks of any one of claims 1-4.

### Claim 6

An electrochemical cell, comprising:
a container;
at least one electrochemical stack in the container, the electrochemical stack comprising at least:
a solid-state electrolyte;
a positive electrode comprising a liquid electrolyte or a gel electrolyte;
a positive electrode current collector; and
a seal impermeable to the liquid electrolyte or the gel electrolyte that bonds to the positive electrode current collector and to the solid-state electrolyte, wherein the seal is not bonded to the container.

### Claim 7 (depends on 6)

The electrochemical cell of claim 6, wherein the seal comprises a material selected from the group consisting of polyisobutylene (PIB), polyether ether ketone (PEEK), polypropylene (PP), a polyolefin, and combinations thereof.

### Claim 8 (depends on 6, 7)

The electrochemical cell of claim 6 or 7, wherein the seal comprises a top layer and a bottom layer, and wherein the top layer of the seal and the bottom layer of the seal comprise the same material.

### Claim 9 (depends on 8)

The electrochemical cell of claim 8, wherein the seal further comprises a middle layer, and wherein the middle layer of the seal is a different material than the top layer or bottom layer.

### Claim 10 (depends on 8, 9)

The electrochemical cell of claim 8 or 9, wherein the top layer and the bottom layer comprise PIB.

### Claim 11 (depends on 6, 7, 8, 9, 10)

A battery comprising at least one electrochemical cell of any one of claims 6-10.

### Claim 12 (depends on 6, 7, 8, 9, 10, 11)

The electrochemical cell of any one of claims 6-11, wherein the seal has a hardness of 30-150 durometer.

### Claim 13 (depends on 6, 7, 8, 9, 10, 11, 12)

A device comprising an electrochemical cell of any one of claim 6-12.

### Claim 14

A method of making an electrochemical cell, comprising:
providing a positive electrode current collector and an electrochemical cell stack on a substrate;
applying a seal material on to the positive electrode current collector;
wherein the electrochemical stack comprises:
a solid-state electrolyte;
a positive electrode comprising a liquid electrolyte or a gel electrolyte;
wherein the seal material is impermeable to the liquid electrolyte or the gel electrolyte, and wherein the seal material bonds to the positive electrode current collector and to the solid-state electrolyte;
enclosing the cell stack within a pressure ring; and
applying at least 3 pounds per square inch (PSI) to the electrochemical cell.

### Claim 15 (depends on 14)

The method of claim 14, wherein the electrochemical stack further comprises a negative electrode current collector.

### Claim 16 (depends on 14, 15)

The method of claim 14 or 15, wherein the electrochemical stack further comprises a lithium metal negative electrode.

### Claim 17 (depends on 14, 15, 16)

The method of any one of claims 14-16, comprising applying the seal material after assembling the electrochemical stack.

### Claim 18 (depends on 14, 15, 16, 17)

The method of any one of claims 14-17, wherein applying the seal material comprises spraying the seal material.

### Claim 19 (depends on 14, 15, 16, 17)

The method of any one of claims 14-17, wherein applying the seal material comprises coating the seal material.

### Claim 20 (depends on 14, 15, 16, 17)

The method of any one of claims 14-17, wherein applying the seal material is comprises injection molding.

### Claim 21 (depends on 20)

The method of claim 20, wherein the injection molding occurs at a pressure lower than atmospheric pressure.

### Claim 22 (depends on 21)

The method of claim 21, wherein the injection molding occurs at a minimum pressure of 0.00001 atm.

### Claim 23 (depends on 14, 15, 16, 17, 18, 19, 20, 21, 22)

The method of any one of claims 14-22, wherein the seal material is in contact with the solid-state electrolyte.

### Claim 24 (depends on 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)

The method of any one of claims 14-23, wherein the seal material is selected from the group consisting of polyisobutylene (PIB), polyether ether ketone (PEEK), polypropylene, a polyolefin, and combinations thereof.

### Claim 25 (depends on 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)

The method of any one of claims 14-23, wherein the seal material is selected from the group consisting of polyisobutylene (PIB), polyether ether ketone (PEEK), and combinations thereof.

### Claim 26 (depends on 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)

The method of any one of claims 14-25, wherein the pressure ring comprises polyether ether ketone (PEEK).

### Claim 27 (depends on 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)

The method of any one of claims 14-26, comprising heating the substrate to at least 50° C.

### Claim 28

A method of making an electrochemical cell, comprising:
providing a positive electrode current collector on a substrate;
applying a seal material on the positive electrode current collector;
providing a pressure ring;
providing an electrochemical stack on the seal material and within the pressure ring,
wherein the electrochemical stack comprises:
a solid-state electrolyte;
a positive electrode comprising a liquid electrolyte or a gel electrolyte; and
wherein the seal material is impermeable to the liquid electrolyte or the gel electrolyte that bonds to the positive electrode current collector and to the solid-state electrolyte; and
applying at least 3 pounds per square inch (PSI) to the electrochemical cell.

### Claim 29 (depends on 28)

The method of claim 28, wherein the pressure ring comprises polyether ether ketone (PEEK).

### Claim 30 (depends on 28, 29)

The method of claim 28 or 29, wherein the electrochemical stack further comprises a negative electrode current collector.

### Claim 31 (depends on 28, 29, 30)

The method of any one of claims 28-30, wherein the electrochemical stack further comprises a lithium metal negative electrode.