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,   wherein the intercalation chemistry active material and the conversion chemistry active material are homogenously mixed in the cathode region.   
     
     
         2 - 6 . (canceled) 
     
     
         2 . The device of  claim 1  wherein the electrolyte region comprises lithium silicon sulfide. 
     
     
         3 . The device of  claim 1  wherein the electrolyte region comprises a lithium, phosphorus, tin, and/or silicon sulfide. 
     
     
         4 . The device of  claim 1  wherein the electrolyte region comprises a garnet electrolyte or a sulfide electrolyte. 
     
     
         5 . 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. 
     
     
         6 . The device of  claim 1  wherein the intercalation chemistry active material comprises LiFePO 4 , Li x Ti y O z , LiNi x Mn 2-x O 4 , LiCoO 2 , Li(NiCoMn)O 2 , and/or Li(NiCoAl)O 2  materials. 
     
     
         7 . The device of  claim 1  wherein the intercalation chemistry active material is selected from Li(NiCoMn)O 2 , Li(NiCoAl)O 2 , and Nickel Cobalt Aluminum Oxides (NCA), wherein the intercalation chemistry active material has a discharge voltage between 1.3V and 2.5V. 
     
     
         13 . (canceled) 
     
     
         8 . The device of  claim 1  wherein the conversion chemistry active material is characterized by a first upper voltage level and the intercalation chemistry active material is characterized by a second upper voltage level, the first upper voltage level being lower than the second upper voltage level. 
     
     
         9 . (canceled) 
     
     
         10 . 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. 
     
     
         11 .- 18 . (canceled) 
     
     
         12 . The device of  claim 1  wherein the cathode region comprises a conversion material and at least two different types of intercalation chemistry active materials. 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . The system of  claim 14  wherein the BMS is configured to charge the battery pack by pulse charges, wherein the intercalation chemistry active material comprises LiFePO 4 , Li x Ti y O z , LiNi x Mn 2-x O 4 , LiCoO 2 , Li(NiCoMn)O 2 , and/or Li(NiCoAl)O 2  materials 
     
     
         24 . The system of  claim 14  wherein the intercalation chemistry active material is selected from Li(NiCoMn)O 2  and/or Li(NiCoAl)O 2  materials wherein the intercalation chemistry active material has a discharge voltage between 1.3V and 2.5V. 
     
     
         17 .- 31 . (canceled) 
     
     
         18 . An electrochemical device comprising:
 an anode region;   an electrolyte region; and   a cathode region comprising one or more intercalation chemistry active materials and a conversion chemistry active material, wherein the intercalation chemistry active material and the conversion chemistry active material are homogenously mixed in the cathode region;   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,   wherein the intercalation chemistry active material comprises LiFePO 4 , Li x Ti y O z , LiNi x Mn 2-x O 4 , LiCoO 2 , Li(NiCoMn)O 2 , and/or Li(NiCoAl)O 2  materials.   
     
     
         19 . The electrochemical device of claim  32 , wherein the one or more intercalation chemistry active materials is material is selected from Li(NiCoMn)O 2  and/or Li(NiCoAl)O 2  materials, wherein the intercalation chemistry active material has a discharge voltage between 1.3V and 2.5V. 
     
     
         20 . (canceled) 
     
     
         21 .- 59 . (canceled) 
     
     
         60 . The device of  claim 1 , wherein the conversion chemistry active material particles when charged comprise FeF 3 ; and wherein the conversion chemistry active material particles when discharged comprise LiF and a nanodimensioned Fe. 
     
     
         61 . The device of  claim 1 , wherein the intercalation chemistry active material particles include a member selected from the group consisting of LiTiO 2 , Li 4.7 Ti 5 O 12 , Li 4 Ti 5 O 12 , and combinations thereof. 
     
     
         62 . The device of  claim 1 , wherein the intercalation chemistry active material particles include a member selected from the group consisting of Li 3-4 TiFe 3 O 8 , Li 2-4 TiV 3 O 5 , Li 3-5 TiMn 3 O 6 , Li 1-3 Ti 2 V 5 O 12 , Li 0-1 La 4 Ti 3 O 12 , Li 1-5 Ti 2 V 3 O 15 , Li 0.67-2 TiVO 4 , Li 1-2 TiVO 5 , Li 7-9 Ti 1.2 NbO 30 , Li 0-1 TiP 2 O 7 , Li 4-5 Ti 3 O 5 , Li 1-2 TiVO 4 , Li 0-1 TiO 2 , Li 4-7 Ti 11 O 24 , Li 1-4 Ti 3 VO 3 , Li 0-1 TiO 2 , Li 0.75-1 TiO 2 , Li 1-2 Ti 2 VO 4 , Li 7-9 Ti 7 Nb 5 O 30 , Li 2-3 TiV 2 O 6 , Li 0-5 Ti 4 VO 8 , Li 0-1 TiO 2 , Li 0-1 TiP 2 O 7 , and combinations thereof. 
     
     
         63 . The device of  claim 1 , wherein the conversion chemistry active material is present in the cathode region at a weight fraction greater than about 80 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 20 w/w % of the active material in the cathode active region. 
     
     
         64 . The device of  claim 1 , wherein the conversion chemistry active material is present in the cathode region at a weight fraction greater than about 85 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 15 w/w % of the active material in the cathode active region. 
     
     
         65 . The device of  claim 1 , wherein the cathode includes a binder, wherein the binder is at least one of polypropylene, ethylene propylene rubber, ethylene pentene copolymer, polyisobutylene, styrene butadiene rubber, polyolefins, polyethylene-co-poly-1-octene, PE-co-poly(methylene cyclopentane, sterioblock polypropylenes, polypropylene polymethylpentene copolymer, polyethylene oxide, silicone, or combinations thereof.