# US 2022/0045328 A1 · Glassy embedded solid-state electrode assemblies, solid-state batteries and methods of making electrode assemblies and solid-state batteries

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- Number: US 2022/0045328 A1
- Document ID: US20220045328A1
- Status: Published application
- Kind: A1
- Application number: 17/303,707
- Filed: 2021-06-04
- Published: 2022-02-10
- Earliest claimed: 2020-08-04
- Assignees: PolyPlus Battery Company
- Applicants: PolyPlus Battery Company
- Inventors: Steven J. Visco; Yevgeniy S. Nimon; Bruce D. Katz; Vitaliy Nimon
- Web page: https://patentgrep.com/patent/US20220045328A1

## CPC

- H01M 4/62: Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
- H01M 4/0416: {involving impregnation with a solution, dispersion, paste or dry powder (H01M4/0438 takes precedence)}
- H01M 4/0471: {involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis}
- 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 4/621: {Binders}
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H01M 10/0562: Solid materials
- H01M 2004/028: {Positive electrodes}
- H01M 2300/0068: inorganic
- 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

Batteries, component structures and manufacturing methods, in particular including a glassy embedded battery electrode assembly having a composite material structure composed of interpenetrating material components including a porous electroactive network including a solid electroactive material, and a continuous glassy medium including a Li ion conducting sulfide glass, can achieve enhanced power output, reduced charging time and/or improved cycle life.

## Claims

### Claim 1

A glassy embedded electrode assembly having first and second opposing major surfaces, the electrode assembly comprising:
a composite material structure composed of first and second interpenetrating material components;
wherein the first material component is a porous electroactive network comprising a solid electroactive material, the network having major opposing surfaces and a pore structure with open pores that extend into the network from the major opposing surfaces, the pores having interior pore surfaces;
wherein the second material component is a continuous glassy medium comprising a Li ion conducting sulfide glass;
wherein the glassy medium encapsulates the electroactive network in the form of a glassy cover region that is substantially devoid of crystalline particles; and
wherein the glassy medium extends into the depth of the electroactive network to form a three-dimensional solid-state interface with the electroactive network.

### Claim 2 (depends on 1)

The glassy embedded electrode assembly of claim 1 wherein the three-dimensional solid-state interface is devoid of reaction products resulting from the Li ion conducting sulfide glass chemically reacting in direct contact with the electroactive material of the network.

### Claim 3 (depends on 2)

The glassy embedded electrode assembly of claim 2 wherein the interface the Li ion conducting sulfide glass is not chemically oxidized in direct contact with the electroactive material of the network.

### Claim 4 (depends on 1)

The glassy embedded electrode assembly of claim 1 wherein the electroactive network is a porous preformed electroactive monolith composed of cathode active material that is of the intercalation type.

### Claim 5 (depends on 1)

The glassy embedded electrode assembly of claim 1 wherein the electroactive network is a porous preformed that is a composite material of discrete electroactive particles held together by a binder material that is thermally stable for its utility as a binder when heated to Tg of the glassy medium.

### Claim 6 (depends on 1)

The glassy embedded electrode assembly of claim 1 wherein the composite material structure is formed by hot isostatic pressing a mixture of Li ion conducting glassy sulfide media particles and electroactive material particles.

### Claim 7

A method of making a glass embedded electrode assembly, the method comprising: i) providing a porous electroactive network comprising cathode active material; ii) coating the electroactive network surfaces with a protective nanofilm that covers the cathode active material surfaces; iii) impregnating the pores of the electroactive network with particles of Li ion conducting sulfide glass to form a glassy electroactive prepreg; and heating the prepreg to cause the glass particles to viscously sinter to each other and form a continuous a glassy medium interpenetrating with the electroactive network.

### Claim 8 (depends on 7)

The method of claim 7 wherein the infiltration step takes place at a temperature at or below 60° C.