Secondary lithium-ion batteries comprising in situ thermal curable solid composite electrolyte

1. A rechargeable lithium-ion battery with an in situ thermally-curable electrolyte, comprising:

at least one cathode with one or more layers selected from lithium manganese oxide, lithium cobalt oxide, lithium nickel manganese cobalt oxide, and/or lithium iron phosphate;

at least one anode with one or more layers selected from carbon black, carbon nanotubes, lithium metal, graphene, and/or graphite;

at least one porous separator having a porosity from approximately 30% to 90%;

a thermally-curable electrolyte precursor solution comprising:

a first crosslinking agent, wherein the first crosslinking agent is represented by formula (I):

C═C—(R 1 ) n —(R 2 ) m —(R 3 ) j —(R 4 ) k —C═C  (I),

wherein R1, R2, R3 and R4 in formula (I) are jointly or independently selected from epoxy, alkoxy, urethane, CN, ethylene oxide, propylene oxide and alkyl; n is 5000 or less and m, j and k are from 1 to 5000; n, m, j and k are integers, respectively;

a second crosslinking agent;

an initiator;

an electrolyte solvent;

an electrolyte salt;

one or more electrolyte additives;

a monomer mixture of polyether and pentaerythritol tetrakis(3-mercaptopropionate) or a monomer polymerization product of poly propylene oxide-co-ethylene oxide tri-acrylate;

wherein the viscosity of the thermally-curable electrolyte precursor solution is below 200 cps such that the thermally-curable electrolyte precursor solution is infiltrated within the separator and the pores inside the cathode and anode layers then cured to form porous separator and porous electrodes fully permeated with a solid electrolyte.

2. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the second crosslinking agent is represented by formula (II):

Rx-S—H  (II),

wherein R is selected from epoxy, ester, and alkyl groups; wherein x is from 1 to 5000.

3. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the initiator is selected from azobis(iso-butyronitrile), 2,2′-azobis(2,4-dimethylvaleronitrile) and azobisdimethyl-valeronitrile, dimethyl 2,2′-azobis(2-methylpropionate), 2,2′-azobis[2-(2-imidazolin-2-yl)-propane] dihydrochloride, cumene hydroperoxide or di-tert-butyl peroxide.

4. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the first crosslinking agent is in an amount of approximately from 1% to 15% by weight.

5. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the second crosslinking agent is in an amount of approximately from 1% to 15% by weight.

6. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the initiator is in an amount of approximately from 1% to 5% by weight.

7. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the electrolyte solvent is in an amount of approximately from 65% to 86% by weight.

8. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the electrolyte salt is selected from LiPF 6 , LiAsF 6 , LiClO 4 , LiTFSi, LiBF 4 , LiCF 3 SO 3 , LiN(CF 3 SO 2 ) 2 , LiFSI or LiSBF 6 .

9. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the additives are selected from one or more of fluoroethylene carbonate, dimethylglycol, orthoformate fluoride, tris(2,2,2-trifluoroethyl)orthoformate, 1,1,1,3,3,3-hexafluoro-2-propanol, lithium difluoro(ethanedioato)borate, lithium bis(oxalate)borate, vinylene carbonate, 1,3-propane sultone, membrane-forming agents, fire retardants, and/or ceramic particles.

10. The rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 1 , wherein the thermally-cured electrolyte precursor solution is cured at 40° C. to 80° C. for approximately 20 minutes to 6 hours.

11. A method for fabricating a rechargeable lithium-ion battery with an in situ thermally-curable electrolyte comprising:

stacking or rolling at least one cathode, at least one porous separator and at least one anode to form a layered structure;

inserting the layered structure into a battery housing;

providing the thermally-curable electrolyte precursor solution of claim 1 and pouring the thermally-curable electrolyte precursor solution into the battery housing;

sealing the battery housing and heating the battery housing to cure the electrolyte precursor solution into a solid electrolyte and form a separator fully infused with the solid electrolyte;

wherein viscosity of the thermally-curable electrolyte precursor solution is below 200 cps such that the thermally-curable electrolyte precursor solution is infiltrated within the separator and the pores inside the cathode and anode layers.

12. The method for fabricating a rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 11 , wherein the battery is a pouch battery or a cylindrical battery.

13. The method for fabricating a rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 11 , wherein said heating the battery housing is for approximately 20 minutes to 6 hours.

14. The method for fabricating a rechargeable lithium-ion battery with an in situ thermally-curable electrolyte of claim 11 , wherein said heating the battery housing to form the solid electrolyte is at approximately from 40° C. to 80° C.