Nano-engineered coatings for anode active materials, cathode active materials, and solid-state electrolytes and methods of making batteries containing nano-engineered coatings
The present disclosure relates to a nano-engineered coating for cathode active materials, anode active materials, and solid state electrolyte materials for reducing corrosion and enhancing cycle life of a battery, and processes for applying the disclosed coating. Also disclosed is a solid state battery including a solid electrolyte layer having a solid electrolyte particle coated by a protective coating with a thickness of 100 nm or less. The protective coating is obtained by atomic layer deposition (ALD) or molecular layer deposition (MLD). Further disclosed is a solid electrolyte layer for a solid state battery, including a porous scaffold coated by a first, solid electrolyte coating. The solid electrolyte coating has a thickness of 60 μm or less and a weight loading of at least 20 wt. % (or preferable at least 40 wt. % or at least 50 wt. %). Further disclosed is a cathode composite layer for a solid state battery.
1. A solid state battery comprising a solid electrolyte layer which comprises a solid electrolyte particle coated by a protective coating, wherein the protective coating has a thickness of 100 nm or less and is obtained by atomic layer deposition (ALD) or molecular layer deposition (MLD),
wherein the deposited protective coating has an ionic conductivity of 10 −6 S cm −1 or lower, and the solid electrolyte layer maintains an ionic conductivity of at least 10 −6 S cm −1 after 1 hour of exposure to ambient air;
wherein the solid electrolyte particle coated by the protective coating is castable using a solvent comprising water or a solvent comprising N′-methylpyrrolidone (NMP); and
wherein the solid electrolyte particle is encapsulated within the protective coating.
2. The solid state battery of claim 1 , wherein the solid electrolyte particle comprises a lithium-conducting sulfide-based, phosphide-based or phosphate-based compound, an ionically-conductive polymer, a lithium or sodium super-ionic conductor, or an ionically conductive oxide or oxyfluoride.
3. The solid state battery of claim 1 , wherein the solid electrolyte particle has a diameter of 60 μm or less.
4. The solid state battery of claim 1 , wherein the solid electrolyte particle has a diameter of 10-500 nm and a surface area of 0.01 m 2 /g to 200 m 2 /g.
5. The solid state battery of claim 1 , wherein the protective coating has a thickness of 0.2-25 nm.
6. The solid state battery of claim 1 , wherein the protective coating is adjacent coated or uncoated particles in the solid electrolyte layer.
7. The solid state battery of claim 1 , wherein the protective coating comprises alumina or titania.
8. The solid state battery of claim 7 wherein the protective coating comprises alumina.
9. The solid state battery of claim 1 , further comprising a cathode composite layer in contact with the solid electrolyte layer.
10. The solid state battery of claim 1 , wherein the cathode composite layer comprises a cathode active material mixed with a conductive additive and a solid electrolyte.
11. The solid state battery of claim 10 , wherein the cathode active material comprises a lithium metal oxide, lithium metal phosphate, sulfur, lithium sulfide, metal sulfide, lithium metal sulfide, metal fluoride, metal oxyfluoride, lithium metal fluoride, lithium metal oxyfluoride, or lithium excess material.
12. The solid state battery of claim 10 , wherein the cathode active material comprises a cathode particle coated by a protective coating having a thickness of 100 nm or less, wherein optionally the protective coating of the cathode particle in the cathode composite layer and the protective coating of the solid electrolyte particle in the solid electrolyte layer comprise the same material.
13. The solid state battery of claim 1 , further comprising an anode composite layer in contact with the solid electrolyte layer.
14. The solid state battery of claim 13 , wherein the anode composite layer comprises an anode active material mixed with a conductive additive and a solid electrolyte.
15. The solid state battery of claim 14 , wherein the anode active material comprises a carbon-based material, silicon, tin, aluminum, germanium, a metal alloy, a prelithiated metal, lithium, an oxide compound, or a mixture or combination thereof.
16. The solid state battery of claim 14 , wherein the anode active material comprises an anode particle coated by a protective coating having a thickness of 100 nm or less, optionally wherein the protective coating of the anode particle in the anode composite layer and the protective coating of the solid electrolyte particle in the solid electrolyte layer comprise the same material.
17. The solid state battery of claim 1 , which has a first cycle discharge capacity that is at least 100% higher than a corresponding solid state battery in which the solid electrolyte particle in the solid electrolyte layer is not coated by a protective coating when both the solid state battery and the corresponding solid state battery are fabricated under the same environment.
18. The solid state battery of claim 1 , wherein the protective coating controls growth of native oxide on the solid electrolyte particle in ambient air to no more than about 5 nm in thickness, and/or maintains an oxygen content of the solid electrolyte particle to no more that about 5% after exposure to ambient air for 24 hours.
19. A cathode composite layer for a solid state battery, comprising a cathode active material mixed with a solid electrolyte material, wherein the cathode active material comprises a plurality of cathode particles each coated by a first protective coating, and wherein the solid electrolyte material comprises a plurality of solid electrolyte particles each coated by a second protective coating.
20. The cathode composite of claim 19 wherein the protective coating comprises Al 2 O 3 , TiO 2 , or LiPON.
21. The cathode composite of claim 20 wherein the protective coating comprises Al 2 O 3 .
22. The cathode composite of claim 20 , wherein the cathode particles comprise NCA, NMC, or LMR-NMC.
23. A solid state battery comprising a solid electrolyte layer which comprises a solid electrolyte particle coated by a protective coating, wherein the protective coating has a thickness of 100 nm or less and is obtained by atomic layer deposition (ALD) or molecular layer deposition (MLD),
wherein the solid electrolyte particle comprises one or more selected from the group: a lithium-conducting sulfide-based, phosphide-based or phosphate-based compound; an ionically-conductive polymer; a lithium and/or sodium super-ionic conductor (LiSICON, NaSICON or LiNaSICON); an ionically-conductive oxide or oxyfluoride; a Garnet; a Perovskite; Na Beta alumina; xLi 2 S−(1−x) P 2 S 5 where x is a molar ratio and ranges from 10 to 90; Li x Ge y P z S 4 where 2.3<x<4, 0<y<1 and 0<z<1; Lis 3 P; lithium aluminum titanium phosphate; an ionically-conductive polymer based upon polyethylene oxide or thiolated materials (e.g. polyethylene-diethoxythiophene or PEDOT); lithium lanthanum titanate, tantalate or zirconate; lithiated and non-lithiated bismuth or niobium oxide and oxyfluoride; lithiated and non-lithiated barium titanate; lithium phosphorus sulfide; and lithium tin phosphorus sulfide;
wherein the protective coating comprises one or more selected from the group: a metal oxide; a metal nitride; a metal oxynitride; a metal carbide; a metal oxycarbide; a metal carbonitride; a metal phosphate; a metal sulfide; a metal fluoride; a metal oxyfluoride; a metal oxyhalide; a non-metal oxide; a non-metal nitride; a non-metal carbonitride; a non-metal fluoride; a non-metallic organic complex; a non-metal oxyfluoride; alumina; and titania; and wherein the solid electrolyte particle is encapsulated within the protective coating.
24. The solid state battery of claim 23 , wherein the protective coating is adjacent coated or uncoated particles in the solid electrolyte layer.
25. The solid state battery of claim 23 , wherein the protective coating comprises alumina or titania.
26. The solid state battery of claim 25 wherein the protective coating comprises alumina.