Subfluorinated Graphite Fluorides as Electrode Materials

Abstract

Subfluorinated graphite fluorides of formula CF x wherein x is in the range of 0.06 to 0.63, e.g., 0.10 to 0.46, are used as electrode materials in electrochemical devices that convert chemical energy to electrical current, e.g., batteries. The invention additionally provides methods of manufacturing electrodes with the subfluorinated graphite fluorides, as well as primary and secondary batteries containing such electrodes.

1 . An electrochemical device comprising an anode, a cathode, and an ion-transporting material therebetween, wherein the cathode comprises a subfluorinated graphite fluoride of formula CF x  in which x is in the range of 0.06 to 0.63. 
   
   
       2 . The device of  claim 1 , wherein x is in the range of 0.06 to 0.52. 
   
   
       3 . The device of  claim 2 , wherein x is in the range of 0.10 to 0.52. 
   
   
       4 . The device of  claim 3 , wherein x is in the range of 0.10 to 0.46. 
   
   
       5 . The device of  claim 4 , wherein x is in the range of 0.33 to 0.46. 
   
   
       6 . The device of  claim 1 , wherein the subfluorinated graphite fluoride comprises a particulate material. 
   
   
       7 . The device of  claim 6 , wherein the subfluorinated graphite fluoride has an average particle size in the range of about 1 micron to about 10 microns. 
   
   
       8 . The device of  claim 7 , wherein the subfluorinated graphite fluoride has an average particle size in the range of about 4 microns to about 7.5 microns. 
   
   
       9 . The device of  claim 8 , wherein the subfluorinated graphite fluoride has an average particle size of about 4 microns. 
   
   
       10 . The device of  claim 1 , wherein the subfluorinated graphite fluoride is in a composition further comprising a conductive diluent and a binder. 
   
   
       11 . The device of  claim 10 , wherein the conductive diluent is selected from acetylene black, carbon black, powdered graphite, cokes, carbon fibers, metallic powders, and combinations thereof. 
   
   
       12 . The device of  claim 11 , wherein the conductive diluent is acetylene black. 
   
   
       13 . The device of  claim 10 , wherein the binder is polymeric. 
   
   
       14 . The device of  claim 13 , wherein the binder is a fluorinated hydrocarbon polymer. 
   
   
       15 . The device of  claim 1 , wherein the anode comprises a source of ions of a metal selected from Groups 1, 2, and 3 of the Periodic Table of the Elements. 
   
   
       16 . The device of  claim 15 , wherein the ions are lithium ions. 
   
   
       17 . The device of  claim 16 , wherein the source of lithium ions is selected from lithium metal, a lithium alloy, and a carbon-lithium material. 
   
   
       18 . The device of  claim 17 , wherein the source of lithium ions is lithium metal. 
   
   
       19 . The device of  claim 1 , wherein the ion-transporting material physically separates the anode and the cathode and prevents direct electrical contact therebetween. 
   
   
       20 . An electrochemical device comprising an anode, a cathode, and an ion-transporting material therebetween, wherein the cathode comprises a subfluorinated graphite fluoride of formula CF x  in which x is in the range of 0.06 to 0.63; wherein said subfluorinated graphite fluoride of said cathode is made by contacting a graphite powder having an average particle size in the range of 1 micron to 10 microns with a gaseous source of elemental fluorine at a temperature in the range of 375° C. to 400° C. for a time period of 5 to 80 hours.