Rechargeable battery with voltage activated current interrupter
A high energy density rechargeable metal-ion battery includes an anode energy layer, a cathode energy layer, a separator for separating the anode and the cathode energy layers, an anode current collector for transferring electrons to and from the anode energy layer, the battery characterized by a maximum safe voltage for avoiding overcharge, and an interrupt layer that interrupts current within the battery upon exposure to voltage in excess of the maximum safe voltage. The interrupt layer is between the anode energy layer and anode current collector. When unactivated, it is laminated to the anode current collector, conducting current therethrough. When activated, the interrupt layer delaminates from the anode current collector, interrupting current therethrough. The interrupt layer includes a voltage sensitive decomposable component that upon exposure to voltage in excess of the maximum safe voltage decomposes, evolving a gas, delaminating the interrupt layer from the anode current collector, interrupting current therethrough.
1. A method for interrupting a recharging process for a high energy density rechargeable metal-ion battery upon exposure to a voltage exceeding a threshold voltage, the high energy density rechargeable metal-ion battery comprising an anode energy layer, a cathode energy layer, a separator between the anode energy layer and the cathode energy layer, and current collector coupled with each one of the anode energy layer and the cathode energy layer for transferring electrons to and from a corresponding energy layer, the method comprising:
in response to an overcharging of the high energy density rechargeable metal-ion battery in which the high energy density rechargeable metal-ion battery is exposed to the voltage exceeding the threshold voltage, interrupting the overcharging by evolving a gas by decomposition of a voltage sensitive decomposable component within a gas generating layer laminated to the current collector coupled with at least one of the anode energy layer and the cathode energy layer, the voltage sensitive decomposable component including carboxymethyl cellulose (CMC) doped with anions, the gas generating layer further including a carbon (C) additive and a binder that increases the binding of carboxymethyl cellulose (CMC) particles by partially filling an interstitial space within the gas generating layer and a conductive component dispersed within the binder, the interstitial space within the gas generating layer being partially unfilled such that the gas generating layer remains porous and permeable to ionic charge carriers, the gas generating layer serving as a current interrupter with the evolved gas delaminating the gas generating layer from the current collector upon exposure to the voltage exceeding the threshold voltage, and the overcharging of the high energy density rechargeable metal-ion battery being interrupted when the gas generating layer is delaminated from the current collector by an evolution of gas within the gas generating layer.
2. The method of claim 1 , wherein the gas generating layer is compacted to reduce the interstitial space between the coated particles of carboxymethyl cellulose (CMC) and to increase binding between the carboxymethyl cellulose (CMC) and the binder.
3. The method of claim 1 , wherein the gas generating layer comprises greater than 30% carboxymethyl cellulose (CMC) by weight.
4. The method of claim 1 , wherein the gas generating layer comprises greater than 50% carboxymethyl cellulose (CMC) by weight.
5. The method of claim 1 , wherein the gas generating layer comprises greater than 70% carboxymethyl cellulose (CMC) by weight.
6. The method of claim 1 , wherein the gas generating layer comprises greater than 75% carboxymethyl cellulose (CMC) by weight.
7. The method of claim 1 , wherein the gas generating layer comprises greater than 80% carboxymethyl cellulose (CMC) by weight.
8. The method of claim 1 , wherein the gas generating layer is sacrificial at voltages above the threshold voltage.
9. The method of claim 8 , wherein the ceramic powder that-chemically decomposes when exposed to voltages above the threshold voltage.
10. The method of claim 1 , wherein the gas is fire retardant.
11. The method of claim 1 , wherein the gas generating layer comprises 1% to 99% carboxymethyl cellulose (CMC) by weight.