Conductive-polymer-coated electrode particles

Abstract

An electro-active compound particulate coated with a conducting polymer composition finds use in electrochemical cell electrodes.

What is claimed is:  
     
         1 . A particulate material comprising a cathode-active material coated with a conducting polymer composition.  
     
     
         2 . The cathode comprising particles of a cathode-active material coated with a conducting polymer composition.  
     
     
         3 . A cathode according to    claim 2    wherein said conducting polymer composition comprises a major amount of a polymer selected from the group consisting of: polyaniline, polyacetylene, polyquinoline, polyquinoxaline, poly(p-phenylene sulfite), poly)(phenylquinoxaline), poly(p-phenylene), polypyrrole, and polyphthalocyaninesiloxane, and a minor amount of capable dopant.  
     
     
         4 . A cathode according to    claim 2    wherein said conducting polymer composition comprises a major amount of polyaniline and a minor amount of a compatible dopant.  
     
     
         5 . A cathode according to    claim 4    wherein said conducting polymer composition comprises a protonated polyaniline salt.  
     
     
         6 . A particulate according to    claim 1    wherein said cathode-active material is an intercalation compound.  
     
     
         7 . A particulate according to    claim 1    wherein said cathode-active material is a lithium intercalation compound.  
     
     
         8 . A particulate according to    claim 1    wherein said cathode-active material is a chalcogenide.  
     
     
         9 . A particulate according to    claim 1    wherein said cathode-active material is an oxide of a metal selected from the group consisting of V, Mn, Co, Ni, Cr, Ti, Mo, and Nb.  
     
     
         10 . A particulate according to    claim 1    wherein said cathode-active material is vanadium oxide.  
     
     
         11 . A particulate according to    claim 1    wherein said cathode-active material is V 6 O 13 .  
     
     
         12 . A particulate according to    claim 1    wherein said cathode-active material is selected from the group consisting of LiV 3 O 8 , V 6 O 13 , LiMn 2 O 4 , LiCoO 2 , LiNiO 2 , ω-V 2 O 5  and ε-Cu 0.2 V 2 O 5 .  
     
     
         13 . A mixture comprising: 
 a cathode-active material in particulate form;    a solubilized conducting polymer; and    a solvent for said conducting polymer.    
     
     
         14 . A mixture according to    claim 13    whereif said solubilized conducting polymer comprises a protonated polyaniline salt and a solvent selected from the group consisting of pyrrolidine, tripropylene, tripropylamine, xylene, chloromethane, m-cresol, formic acid and dimethylsulfoxide.  
     
     
         15 . A cathode paste comprising: 
 a solid matrix forming polymer precursor;    a particulate comprising cathode-active material particles coated with a conducting polymer composition; and    a compatible electrolyte solvent.    
     
     
         16 . A method of making a product particulate comprising cathode-active material particles coated with a conducting polymer composition for use in solid cathodes comprises the steps of: 
 solubilizing a conductive polymer composition with a solvent;    mixing said solubilized polymer composition with particles of cathode-active material to form a mixture;    removing substantially all said solvent from said mixture to produce said product particulate.    
     
     
         17 . A method of making a solid cathode comprising the steps of: 
 forming a cathode paste;    coating the cathode paste onto a substrate; and    curing said paste to a solid cathode;    wherein said cathode paste comprises: 
 a solid matrix forming polymer precursor;  
 a particulate comprising a cathode-active material coated with a conducting polymer; and  
 a compatible electrolyte solvent.  
   
     
     
         18 . A method according to    claim 17    wherein said electrolyte solvent is an aprotic solvent.  
     
     
         19 . A method according to    claim 17    wherein said electrolyte solvent is selected from the group consisting of glymes, organic carbonates, and mixtures thereof.  
     
     
         20 . A method according to    claim 17    wherein said electrolyte solvent is selected from the group consisting of triglyme, propylene carbonate and mixtures thereof.  
     
     
         21 . An electrochemical cell comprising; 
 an anode composed of compatible anodic materials;    a cathode composed of compatible cathodic materials; and    a solid electrolyte interposed therebetween;    wherein said solid electrolyte comprises: 
 a solid polymer matrix,  
 an inorganic ion salt, and  
 an electrolyte solvent; and  
 wherein said cathode comprises particles of a cathode-active material coated with a conducting polymer composition.  
   
     
     
         22 . A battery comprising at least two cells of    claim 21   .