Silicon based lithium ion battery and improved cycle life of same

Abstract

Silicon-dominate battery electrodes, battery cells utilizing the silicon-dominate battery electrodes, and methods of manufacturing are disclosed. Such a battery cell includes a cathode, a separator, an electrolyte, and an anode. The anode comprises a current collector and active material on the current collector. The active material layer includes at least 50% silicon. A ratio of the electrolyte to Ah is over 2 g/Ah.

What is claimed is: 
     
         1 . A battery cell comprising:
 a cathode;   a separator;   an electrolyte; and   an anode;   wherein the anode comprises a current collector and active material layer on the current collector;   wherein the active material layer comprises at least 50% silicon; and   wherein the electrolyte comprises 0.02 to 0.1 mL/cm 2  of the anode that participates in an electrochemical reaction.   
     
     
         2 . The battery cell of  claim 1 , wherein the electrolyte comprises 0.005 to 0.05 mL/cm 2  of the anode that participates in an electrochemical reaction. 
     
     
         3 . The battery cell of  claim 1 , wherein a ratio of the electrolyte to Ah for the battery cell is between 2 g/Ah and 10 g/Ah. 
     
     
         4 . The battery cell of  claim 1 , wherein a ratio of the electrolyte to Ah is between 2 g/Ah and 5 g/Ah. 
     
     
         5 . The battery cell of  claim 1 , wherein a ratio of the electrolyte to Ah is between 2.4 g/Ah and 10 g/Ah. 
     
     
         6 . The battery cell of  claim 1 , wherein a ratio of the electrolyte to Ah is between 2.4 g/Ah and 5 g/Ah. 
     
     
         7 . The battery cell of  claim 1 , wherein a porosity of the active material layer is less than 70%. 
     
     
         8 . The battery cell of  claim 1 , wherein a porosity of the active material layer is less than 60%. 
     
     
         9 . The battery cell of  claim 1 , wherein a porosity of the active material layer is less than 50%. 
     
     
         10 . The battery cell of  claim 1 , wherein a porosity of the active material layer is less than 40%. 
     
     
         11 . The battery cell of  claim 1 , wherein a porosity of the active material layer is less than 30%. 
     
     
         12 . The battery cell of  claim 1 , wherein a second ratio of a thickness of the current collector to a thickness of the active material layer is greater than 0.5. 
     
     
         13 . The battery cell of  claim 1 , wherein a second ratio of a thickness of the current collector to a thickness of the active material layer is greater than 0.66. 
     
     
         14 . The battery cell of  claim 1 , wherein a second ratio of a thickness of the current collector to a porosity-adjusted active material layer thickness of the active material layer is greater than 0.25. 
     
     
         15 . The battery cell of  claim 1 , wherein a second ratio of a thickness of the current collector to a porosity-adjusted active material layer thickness of the active material layer is greater than 0.33. 
     
     
         16 . The battery cell of  claim 1 , wherein a second ratio of a thickness of the current collector to a porosity-adjusted active material layer thickness of the active material layer is greater than 0.5. 
     
     
         17 . The battery cell of  claim 1 , wherein a second ratio of a thickness of the current collector to a porosity-adjusted active material layer thickness of the active material layer is greater than 0.6. 
     
     
         18 . The battery cell of  claim 1 , wherein a second ratio of a thickness of the current collector to a porosity-adjusted active material layer thickness of the active material layer is greater than 1. 
     
     
         19 . The battery cell of  claim 1 , wherein a second ratio of a thickness of the current collector to a porosity-adjusted active material layer thickness of the active material layer is greater than 1.3. 
     
     
         20 . The battery cell of  claim 1 , wherein the active material layer further comprises a pyrolyzed binder.