Hybrid electrodes with both intercalation and conversion materials

Abstract

The disclosure set forth herein is directed to battery devices and methods therefor. More specifically, embodiments of the instant disclosure provide a battery electrode that comprises both intercalation chemistry material and conversion chemistry material, which can be used in automotive applications. There are other embodiments as well.

1 . An electrochemical device comprising:
 an anode region;   an electrolyte region; and   a cathode region comprising an intercalation chemistry active material and a conversion chemistry active material,   wherein the electrolyte region is positioned between the anode region and the cathode region,   wherein the conversion chemistry active material is present in the cathode region at a weight fraction greater than about 70 w/w % of the active material in the cathode region;   wherein the intercalation chemistry active material is present in the cathode region at a weight fraction less than about 30 w/w % of the active material in the cathode active region.   
     
     
         2 . The device of  claim 1  wherein the intercalation chemistry active material and the conversion chemistry active material are substantially segregated into two layers. 
     
     
         3 . The device of  claim 1  wherein the intercalation chemistry active material and the conversion chemistry active material are homogenously mixed in the cathode region. 
     
     
         4 . The device of  claim 1  wherein the intercalation chemistry active material and the conversion chemistry active material are graded within the cathode region such that the intercalation chemistry active material is in higher concentration proximate to the electrolyte. 
     
     
         5 . (canceled) 
     
     
         6 . The device of  claim 2  wherein the intercalation chemistry active material layer is positioned between the conversion chemistry active material layer and the electrolyte region. 
     
     
         7 . The device of  claim 1  further comprising an anode current collector. 
     
     
         8 . The device of  claim 1  wherein the electrolyte region is substantially solid. 
     
     
         9 . The device of  claim 1  wherein the electrolyte region comprises a garnet electrolyte or a sulfide electrolyte. 
     
     
         10 . The device of  claim 1  wherein the conversion chemistry active material is selected from the group consisting of FeF 2 , NiF 2 , FeO x F 3-2x , FeF 3 , MnF 3 , CoF 3 , CuF 2  materials and alloys or combinations thereof. 
     
     
         11 . (canceled) 
     
     
         12 . The device of  claim 1  wherein the intercalation chemistry active material is selected from the group consisting of LiMPO 4  (M=Fe, Ni, Co, Mn), Li x Ti y O z , wherein x is from 0 to 8, y is from 1 to 12, z is from 1 to 24, LiMn 2 O 4 , LiMn 2-a Ni a O 4 , wherein a is from 0 to 2, LiCoO 2 , Li(NiCoMn)O 2 , Li(NiCoAl)O 2 , and Nickel Cobalt Aluminum Oxides [NCA]. 
     
     
         13 . (canceled) 
     
     
         14 . The device of  claim 1  wherein the conversion chemistry material is characterized by a first upper voltage level and the intercalation chemistry material is characterized by a second upper voltage level, the first upper voltage level being lower than the second upper voltage level. 
     
     
         15 . The device of  claim 1  wherein the conversion chemistry active material is characterized by a conversion voltage which is lower than the intercalation voltage of the intercalation chemistry active material. 
     
     
         16 . The device of  claim 1  wherein the conversion chemistry active material is characterized by a conversion voltage which is above the intercalation voltage of the intercalation chemistry active material. 
     
     
         17 . (canceled) 
     
     
         18 . The device of  claim 1  wherein the conversion voltage level during discharge of the conversion chemistry active material is above the intercalation voltage level during discharge of the intercalation chemistry active material. 
     
     
         19 . The device of  claim 1  wherein the cathode region comprises a conversion material and at least two different types of intercalation chemistry active materials. 
     
     
         20 . The device of  claim 19  wherein a first intercalation chemistry active material has a voltage level higher than the upper voltage level of the conversion chemistry active material and a second intercalation chemistry active material has a voltage level lower than the low voltage level of the conversion chemistry active material. 
     
     
         21 . A battery system comprising:
 a battery management system (BMS);   a battery pack comprising a plurality of battery cells, wherein each of the battery cells comprises:
 an anode region; 
 an electrolyte region; and 
 a cathode region comprising an intercalation chemistry material active and a conversion chemistry active material, the electrolyte region being positioned between the anode region and the cathode region, the cathode region being characterized by a first weight, the intercalation chemistry active material being characterized by a second weight, the second weight being less than 20% of the first weight. 
   
     
     
         22 . (canceled) 
     
     
         23 . The system of  claim 21  wherein the BMS is configured to charge the battery pack by pulse charges. 
     
     
         24 . The system of  claim 21  wherein:
 the battery system is electrically coupled to an electric motor; and wherein 
 the BMS charges the battery pack when the electric motor performs regenerative braking and the cathode region is capable of being recharged at a voltage level greater than 4.0V. 
 
     
     
         25 . The system of  claim 21  wherein the cathode region is capable of operating below a cell voltage of about 2V. 
     
     
         26 . The system of  claim 21  wherein the battery pack is characterized by an operating temperature range of between about −30 to 120 degrees Celsius. 
     
     
         27 - 31 . (canceled) 
     
     
         32 . An electrochemical device comprising:
 an anode region;   an electrolyte region; and   a cathode region comprising at least one or more intercalation chemistry active materials and a conversion chemistry active material;   wherein the weight ratio of the conversion chemistry active material to the one or more intercalation chemistry active materials is between 70:30 and 99:1.   
     
     
         33 . (canceled) 
     
     
         34 . The electrochemical device of  claim 32 , wherein the intercalation voltage plateau for the one or more intercalation materials is below the conversion voltage for the conversion chemistry active material. 
     
     
         35 . (canceled) 
     
     
         36 . The electrochemical device of  claim 32 , wherein the operating voltage plateau of the conversion chemistry active material is below the upper operating voltage plateau for the intercalation chemistry active material. 
     
     
         37 . (canceled) 
     
     
         38 . The electrochemical device of  claim 32 , wherein the upper operating voltage plateau of the conversion chemistry active material is between the upper operating voltage plateau and lower operating voltage plateau for the one or more intercalation chemistry active materials. 
     
     
         39 . (canceled) 
     
     
         40 . The electrochemical device of  claim 32 , wherein the lower operating voltage plateau of the one or more intercalation chemistry active materials is above the lower operating voltage plateau for the conversion chemistry active material. 
     
     
         41 . The electrochemical device of  claim 32 , wherein the lower operating voltage of the one or more intercalation chemistry active materials is between the upper operating voltage plateau and the lower operating voltage plateau for the conversion chemistry active material. 
     
     
         42 - 45 . (canceled) 
     
     
         46 . The device of  claim 1  wherein the intercalation chemistry active material comprises at least two different types of intercalation chemistry active materials. 
     
     
         47 . (canceled) 
     
     
         48 . The system of  claim 21  wherein the battery pack is characterized by an operating temperature range of about 70 to 80 degrees Celsius. 
     
     
         49 - 50 . (canceled) 
     
     
         51 . The electrochemical device of  claim 32 , wherein the operating voltage plateau, or upper voltage limit, of the conversion chemistry active material is below the upper operating voltage plateau, or upper voltage limit, of the one or more intercalation chemistry active materials. 
     
     
         52 - 55 . (canceled) 
     
     
         56 . The electrochemical device of  claim 32 , wherein the lower operating voltage plateau of the one or more intercalation chemistry active materials is above the lower operating voltage plateau for the conversion chemistry active material. 
     
     
         57 . The electrochemical device of  claim 32 , wherein the conversion OCV for the conversion chemistry active material is above the intercalation voltage for the one or more intercalation chemistry active materials. 
     
     
         58 . The electrochemical device of  claim 32 , wherein the one or more intercalation chemistry active materials are mixed with the conversion chemistry active material and operate at a lower voltage than the conversion OCV voltage for the conversion chemistry active material. 
     
     
         59 . The electrochemical device of  claim 32 , wherein the one or more intercalation chemistry active materials are mixed with the conversion chemistry active material and operate at both a higher voltage than the intercalation regime voltage range for the conversion chemistry active material and at a lower voltage than the conversion OCV voltage range for the conversion chemistry active material.