Batteries and electrodes for use thereof

Abstract

The present invention generally relates to batteries or other electrochemical devices, and systems and materials for use in these, including novel electrode materials and designs. In some embodiments, the present invention relates to small-scale batteries or microbatteries. For example, in one aspect of the invention, a battery may have a volume of no more than about 5 mm 3 , while having an energy density of at least about 400 W h/l. In some cases, the battery may include a electrode comprising a porous electroactive compound. In some embodiments, the pores of the porous electrode may be at least partially filled with a liquid such as a liquid electrolyte. The electrode may be able to withstand repeated charging and discharging. In some cases, the electrode may have a plurality of protrusions and/or a wall (which may surround the protrusions, if present); however, in other cases, there may be no protrusions or walls. The electrode may be formed from a unitary material. In certain embodiments, a nonporous electrolyte may be disposed onto the electrode. Such an electrolyte may allow ionic transport (e.g., of lithium ions) while preventing dendritic formation due to the lack of pores. In certain embodiments the porous electrode has a surface that is denser than its interior. Other aspects of the invention are directed to techniques of making such electrodes or batteries, techniques of forming electrical connections to and packaging such batteries, techniques of using such electrodes or batteries, or the like.

1 . An article, comprising:
 an electrode formed from a sintered ceramic, the electrode having a porosity of no more than about 50%, at least some of the pores of the electrode being filled with an electrolyte that is a liquid or a polymer.   
     
     
         2 - 4 . (canceled) 
     
     
         5 . The article of  claim 1 , wherein the electrode has a linear strain differential of less than about 20% when the electrode is infiltrated with Li ions. 
     
     
         6 . The article of  claim 1 , wherein the electrode has a linear strain differential of less than about 2% when the electrode is infiltrated with Li ions. 
     
     
         7 . (canceled) 
     
     
         8 . The article of  claim 1 , further comprising a nonporous electrolyte disposed on the electrode. 
     
     
         9 . The article of  claim 1 , wherein the porosity is no more than about 30%. 
     
     
         10 . The article of  claim 9 , wherein the porosity is no more than about 20%. 
     
     
         11 . The article of  claim 10 , wherein the porosity is no more than 15%. 
     
     
         12 . The article of  claim 1 , wherein the ceramic comprises LiCoO 2 . 
     
     
         13 . (canceled) 
     
     
         14 . The article of  claim 1 , wherein the ceramic comprises Li x (Ni a , Co b , Al c )O 2 , wherein x is between about 0 and about 1.5, and the sum of a, b, and c is about 1. 
     
     
         15 . The article of  claim 1 , wherein the ceramic comprises Li x (Mn a , Ni b , Co c )O 2 , wherein x is between about 0 and about 1.5, and the sum of a, b, and c is about 1. 
     
     
         16 - 17 . (canceled) 
     
     
         18 . The article of  claim 8 , wherein the nonporous electrolyte comprises LiPON. 
     
     
         19 . The article of  claim 1 , wherein the article is a battery. 
     
     
         20 . (canceled) 
     
     
         21 . The article of  claim 19 , wherein the battery has a storage density of at least about 400 W h/l. 
     
     
         22 - 27 . (canceled) 
     
     
         28 . The article of  claim 1 , wherein the ceramic has a smallest dimension that is at least about 0.2 mm. 
     
     
         29 . The article of  claim 28 , wherein the ceramic has a smallest dimension that is at least about 0.4 mm. 
     
     
         30 . The article of  claim 29 , wherein the ceramic has a smallest dimension that is at least about 0.6 mm. 
     
     
         31 - 68 . (canceled) 
     
     
         69 . An article, comprising:
 an electrode formed from a sintered ceramic that is able to retain at least about 50% of its initial storage capacity after at least 6 charge-discharge cycles at a C/20 rate.   
     
     
         70 - 181 . (canceled) 
     
     
         182 . An article, comprising:
 an electrode formed from a sintered ceramic, the electrode having a density of at least about 50%, a thickness of at least about 0.25 mm.   
     
     
         183 . (canceled) 
     
     
         184 . The article of  claim 182 , wherein the electrode has a density of at least about 70%. 
     
     
         185 . The article of  claim 182 , wherein the electrode has a density of at least about 80%. 
     
     
         186 - 197 . (canceled) 
     
     
         198 . An article, comprising:
 an electrode formed from a sintered ceramic, the electrode having a product of density, wherein the density is measured as a percent of the theoretical density of the ceramic, and thickness, wherein the thickness is measured in millimeters, of between about 10%-mm and about 150%-mm.   
     
     
         199 - 217 . (canceled) 
     
     
         218 . An article, comprising:
 an electrode formed from a sintered ceramic, the electrode having a charge capacity per unit area of electrode of between about 10 mAh/cm 2  and about 100 mAh/cm 2 .   
     
     
         219 - 239 . (canceled)