Semi-solid electrode cell having a porous current collector and methods of manufacture

Title: Semi-solid electrode cell having a porous current collector and methods of manufacture

An electrochemical cell includes an anode, a semi-solid cathode, and a separator disposed therebetween. The semi-solid cathode includes a porous current collector and a suspension of an active material and a conductive material disposed in a non-aqueous liquid electrolyte. The porous current collector is at least partially disposed within the suspension such that the suspension substantially encapsulates the porous current collector.

Inventors:: Chiang, Yet-Ming; Carter, William Craig; Cross, III, James C.; Bazzarella, Ricardo; Ota, Naoki

Issue Date:: 2017-11-21

OSTI Identifier:: 1409826

Assignee:: 24M Technologies, Inc. (Cambridge, MA) ARPA-E

Patent Number(s):: 9,825,280

Application Number:: 13/606,986

Contract Number:: AR0000102

Resource Relation:: Patent File Date: 2012 Sep 07

Research Org:: 24M Technologies, Inc., Cambridge, MA (United States)

Sponsoring Org:: USDOE

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE

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US Patent Document 12/996938; 20110086258
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220110086258%22.PGNR.&OS=DN/20110086258&RS=DN/20110086258

High Energy Density Redox Flow Device
patent-application, August 2011

Carter, William; Chiang, Yet-Ming; Duduta, Mihai
US Patent Application 12/970773; 20110189520
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220110189520%22.PGNR.&OS=DN/20110189520&RS=DN/20110189520

High Energy Density Redox Flow Device
patent-application, August 2011

Chiang, Yet-Ming; Carter, W. Craig; Ho, Bryan
US Patent Application 12/970753; 20110200848
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220110200848%22.PGNR.&OS=DN/20110200848&RS=DN/20110200848

Energy Transfer Using Electrochemically Isolated Fluids
patent-application, November 2011

Duduta, Mihai; Carter, W. Craig; Chiang, Yet-Ming
US Patent Document 13/083167; 20110274948
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220110274948%22.PGNR.&OS=DN/20110274948&RS=DN/20110274948

Stationary, Fluid Redox Electrode
patent-application, June 2012

Chiang, Yet-Ming; Carter, W. Craig; Duduta, Mihai
US Patent Document 13/212607; 20120164499
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220120164499%22.PGNR.&OS=DN/20120164499&RS=DN/20120164499

Stationary Semi-Solid Battery Module And Method Of Manufacture
patent-application, March 2013

Slocum, Alexander; Doherty, Tristan; Bazzarella, Ricardo
US Patent Application 13/607021; 20130055559
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220130055559%22.PGNR.&OS=DN/20130055559&RS=DN/20130055559

Electrochemical Cells and Methods of Manufacturing the Same
patent-application, November 2013

Bazzarella, Ricardo; Slocum, Alexander H.; Doherty, Tristan
US Patent Document 13/832836; 20130309547
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220130309547%22.PGNR.&OS=DN/20130309547&RS=DN/20130309547

Electrochemical Slurry Compositions and Methods for Preparing the Same
patent-application, December 2013

Doherty, Tristan; Limthongkul, Pimpa; Butros, Asli
US Patent Document 13/832861; 20130337319
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220130337319%22.PGNR.&OS=DN/20130337319&RS=DN/20130337319

Stacked Flow Cell Design And Method
patent-application, January 2014

Slocum, Alexander; Bazzarella, Ricardo; Carter, William
US Patent Application 13/915309; 20140004437
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140004437%22.PGNR.&OS=DN/20140004437&RS=DN/20140004437

Semi-Solid Filled Battery And Method Of Manufacture
patent-application, January 2014

Chiang, Yet-Ming; Carter, William; Limthongkul, Pimpa
US Patent Application 13/915312; 20140030623
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140030623%22.PGNR.&OS=DN/20140030623&RS=DN/20140030623

Energy Storage Modeling And Control
patent-application, February 2014

Carter, W. Craig; Ferrara, Marco; Goroff, Michael
US Patent Application 13/838014; 20140039710
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140039710%22.PGNR.&OS=DN/20140039710&RS=DN/20140039710

High Energy Density Redox Flow Device
patent-application, June 2014

Carter, W. Craig; Chiang, Yet-Ming; Duduta, Mihai
US Patent Application 14/002304; 20140154546
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140154546%22.PGNR.&OS=DN/20140154546&RS=DN/20140154546

Semi-Solid Electrodes Having High Rate Capability
patent-application, June 2014

Chiang, Yet-Ming; Duduta, Mihai; Holman, Richard
US Patent Application 13/872613; 20140170524
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140170524%22.PGNR.&OS=DN/20140170524&RS=DN/20140170524

High Energy Density Redox Flow Device
patent-application, September 2014

Chiang, Yet-Ming; Carter, W. Craig; Duduta, Mihai
US Patent Document 14/276723; 20140248521
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140248521%22.PGNR.&OS=DN/20140248521&RS=DN/20140248521

Asymmetric Battery Having A Semi-Solid Cathode And High Energy Density Anode
patent-application, October 2014

Tan, Taison; Chiang, Yet-Ming; Ota, Naoki
US Patent Application 14/202606; 20140315097
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140315097%22.PGNR.&OS=DN/20140315097&RS=DN/20140315097

Semi-Solid Electrodes With Gel Polymer Additive
patent-application, January 2015

Tan, Taison; Ota, Naoki; Disko, Jeffry
US Patent Application 14/336119; 20150024279
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220150024279%22.PGNR.&OS=DN/20150024279&RS=DN/20150024279

Fuel System Using Redox Flow Battery
patent-application, May 2015

Chiang, Yet-Ming; Bazzarella, Ricardo
US Patent Application 14/306610; 20150129081
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220150129081%22.PGNR.&OS=DN/20150129081&RS=DN/20150129081

Curved Battery Container
patent-application, May 2015

Slocum, Alexander H.
US Patent Document 14/513602; 20150140371
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220150140371%22.PGNR.&OS=DN/20150140371&RS=DN/20150140371

Electrochemical Cells and Methods of Manufacturing the Same
patent-application, June 2015

Bazzarella, Ricardo; Slocum, Alexander H.; Doherty, Tristan
US Patent Document 14/543489; 20150171406
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220150171406%22.PGNR.&OS=DN/20150171406&RS=DN/20150171406

Semi-Solid Electrodes Having High Rate Capability
patent-application, October 2015

Chiang, Yet-Ming; Duduta, Mihai; Holman, Richard
US Patent Document 14/597869; 20150280267
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220150280267%22.PGNR.&OS=DN/20150280267&RS=DN/20150280267

Damage Tolerant Batteries
patent-application, October 2015

Chiang, Yet-Ming; Tan, Taison; Disko, Jeffry
US Patent Document 14/682417; 20150295272
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220150295272%22.PGNR.&OS=DN/20150295272&RS=DN/20150295272

Porous Semi-Solid Electrode and Methods of Manufacturing the Same
patent-application, December 2015

Holman, Richard; Ota, Naoki
US Patent Document 14/732298; 20150357626
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220150357626%22.PGNR.&OS=DN/20150357626&RS=DN/20150357626

Fuel System Using Redox Flow Battery
patent-application, January 2016

Chiang, Yet-Ming; Bazzarella, Ricardo
US Patent Document 14/824664; 20160013507
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160013507%22.PGNR.&OS=DN/20160013507&RS=DN/20160013507

Semi-Solid Electrodes Having High Rate Capability
patent-application, February 2016

Chiang, Yet-Ming; Dudata, Mihai; Holman, Richard
US Patent Document 14/719566; 20160056490
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160056490%22.PGNR.&OS=DN/20160056490&RS=DN/20160056490

Semi-Solid Electrodes Having High Rate Capability
patent-application, February 2016

Chiang, Yet-Ming; Duduta, Mihai; Holman, Richard
US Patent Document 14/875076; 20160056491
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160056491%22.PGNR.&OS=DN/20160056491&RS=DN/20160056491

Systems and Methods for Series Battery Charging
patent-application, April 2016

Taylor, Tony L.; Ota, Naoki; Tan, Taison
US Patent Document 14/879599; 20160105042
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160105042%22.PGNR.&OS=DN/20160105042&RS=DN/20160105042

Pre-Lithiation of Electrode Materials in a Semi-Solid Electrode
patent-application, May 2016

Ota, Naoki; Duduta, Mihai; Fukushima, Takaaki
US Patent Document 14/930991; 20160126543
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160126543%22.PGNR.&OS=DN/20160126543&RS=DN/20160126543

Electrochemical Cells Having Semi-Solid Electrodes and Methods of Manufacturing the Same
patent-application, May 2016

Zagars, Raymond; Curhan, Jeffrey; Doherty, Tristan
US Patent Document 14/932153; 20160133916
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160133916%22.PGNR.&OS=DN/20160133916&RS=DN/20160133916

Stationary Semi-Solid Battery Module and Method of Manufacture
patent-application, June 2016

Slocum, Alexander H.; Doherty, Tristan; Bazzarella, Ricardo
US Patent Document 14/926760; 20160190544
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160190544%22.PGNR.&OS=DN/20160190544&RS=DN/20160190544

High Energy Density Redox Flow Device
patent-application, July 2016

Chiang, Yet-Ming; Carter, W. Craig; Duduta, Mihai
US Patent Document 14/840810; 20160218375
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160218375%22.PGNR.&OS=DN/20160218375&RS=DN/20160218375

Fuel System Using Redox Flow Battery
patent-application, September 2016

Chiang, Yet-Ming; Bazzarella, Ricardo
US Patent Document 15/045718; 20160268621
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160268621%22.PGNR.&OS=DN/20160268621&RS=DN/20160268621

Semi-Solid Electrodes with Porous Current Collectors and Methods of Manufacture
patent-application, October 2016

Ota, Naoki; Tan, Taison
US Patent Document 15/097838; 20160308218
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160308218%22.PGNR.&OS=DN/20160308218&RS=DN/20160308218

Mechanical Systems and Methods for Providing Edge Support and Protection in Semi-Solid Electrodes
patent-application, November 2016

Ota, Naoki; Fukushima, Takaaki; Bazarella, Ricardo
US Patent Document 15/157843; 20160344006
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160344006%22.PGNR.&OS=DN/20160344006&RS=DN/20160344006

Methods for Electrochemical Cell Remediation
patent-application, December 2016

Chiang, Yet-Ming; Woodford, William; Yu, Hiuling Zoe
US Patent Document 15/186928; 20160372802
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220160372802%22.PGNR.&OS=DN/20160372802&RS=DN/20160372802

Asymmetric Battery Having a Semi-Solid Cathode and High Energy Density Anode
patent-application, January 2017

Tan, Taison; Chiang, Yet-Ming; Ota, Naoki
US Patent Document 15/228259; 20170018798
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220170018798%22.PGNR.&OS=DN/20170018798&RS=DN/20170018798

Single Pouch Battery Cells and Methods of Manufacture
patent-application, January 2017

Ota, Naoki; Fukushima, Takaaki; Bazzarella, Ricardo
US Patent Document 15/185625; 20170025646
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220170025646%22.PGNR.&OS=DN/20170025646&RS=DN/20170025646

Optimum Electronic and Ionic Conductivity Ratios in Semi-Solid Electrodes
patent-application, January 2017

Tan, Taison; Ota, Naoki; Woodford, William
US Patent Document 15/013497; 20170025674
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220170025674%22.PGNR.&OS=DN/20170025674&RS=DN/20170025674

Semi-Solid Electrodes Having High Rate Capability
patent-application, February 2017

Chiang, Yet-Ming; Duduta, Mihai; Holma, Richard
US Patent Document 15/148048; 20170033389
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Semi-Solid Electrodes Having High Rate Capability
patent-application, February 2017

Chiang, Yet-Ming; Duduta, Mihai; Holman, Richard
US Patent Document 15/174172; 20170033390
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220170033390%22.PGNR.&OS=DN/20170033390&RS=DN/20170033390

Semi-Solid Lithium Rechargeable Flow Battery
journal, May 2011

Duduta, Mihai; Ho, Bryan; Wood, Vanessa C.
Advanced Energy Materials, Vol. 1, Issue 4, p. 511-516
DOI: 10.1002/aenm.201100152

Conjugated dicarboxylate anodes for Li-ion batteries
journal, January 2009

Armand, M.; Grugeon, S.; Vezin, H.
Nature Materials, Vol. 8, Issue 2, p. 120-125
DOI: 10.1038/nmat2372

Investigation of the Lithiation and Delithiation Conversion Mechanisms of Bismuth Fluoride Nanocomposites
journal, January 2006

Bervas, M.; Mansour, A. N.; Yoon, W.-S.
Journal of The Electrochemical Society, Vol. 153, Issue 4, p. A799-A808
DOI: 10.1149/1.2167951

High-performance lithium battery anodes using silicon nanowires
journal, December 2007

Chan, Candace K.; Peng, Hailin; Liu, Gao
Nature Nanotechnology, Vol. 3, Issue 1, p. 31-35
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Li-Storage via Heterogeneous Reaction in Selected Binary Metal Fluorides and Oxides
journal, January 2004

Li, Hong; Balaya, Palani; Maier, Joachim
Journal of The Electrochemical Society, Vol. 151, Issue 11, p. A1878-A1885
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Rechargeable batteries with organic radical cathodes
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Nakahara, K.; Iwasa, S.; Satoh, M.
Chemical Physics Letters, Vol. 359, Issue 5-6, p. 351-354
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Organic radical battery: nitroxide polymers as a cathode-active material
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Nishide, Hiroyuki; Iwasa, Shigeyuki; Pu, Yong-Jin
Electrochimica Acta, Vol. 50, Issue 2-3, p. 827-831
DOI: 10.1016/j.electacta.2004.02.052

Structure and Electrochemistry of Carbon-Metal Fluoride Nanocomposites Fabricated by Solid-State Redox Conversion Reaction
journal, January 2005

Plitz, I.; Badway, F.; Al-Sharab, J.
Journal of The Electrochemical Society, Vol. 152, Issue 2, p. A307-A315
DOI: 10.1149/1.1842035

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