Phased introduction of lithium into the pre-lithiated anode of a lithium ion electrochemical cell

Abstract

The present invention relates to a method for combining anode pre-lithiation, limited-voltage formation cycles, and accelerating aging via heated storage to maximize specific capacity, volumetric capacity density and capacity retention of a lithium-ion electrochemical cell.

1 . A process of making a lithium ion cell comprising: a) pre-lithiating an anode; b) assembling the anode, a cathode, a separator and electrolyte into a sealed cell; c) charging the cell to a voltage above that of electrolyte reduction but below that voltage that would violate the anode maximum safe lithium capacity; d) discharging or partially discharging the cell; and e) charging the cell to the full voltage. 
     
     
         2 . A process as in  claim 1 , wherein steps (c) and (d) are repeated. 
     
     
         3 . A process as in  claim 1 , wherein an elevated temperature is applied to the cell after step (c) for ½ to 7 or more days. 
     
     
         4 . A process as in  claim 1 , where cell specific capacity and volumetric capacity density are increased. 
     
     
         5 . A process as in  claim 1 , where cell capacity retention is increased. 
     
     
         6 . A process as in  claim 1 , in which steps (c) and (d) are performed at elevated temperatures. 
     
     
         7 . A process of making a lithium ion cell comprising: a) pre-lithiating an anode; b) assembling the anode, a cathode, a separator and electrolyte into a sealed cell; c) heating the cell to an elevated temperature; d) charging the heated cell to a voltage above that of electrolyte reduction but below that voltage that would violate the anode maximum safe lithium capacity; e) optionally discharging the cell and repeating step (c) above;
 f) optionally discharging the cell; and g) charging the cell to the normal full voltage.   
     
     
         8 . A process as in  claim 7 , where cell specific capacity and volumetric capacity density are increased. 
     
     
         9 . A process as in  claim 7 , where cell capacity retention is increased. 
     
     
         10 . A process as in  claim 7 , in which a storage step at elevated temperature is used prior to step g. 
     
     
         11 . A process of making a lithium ion cell comprising: a) providing a pre-lithiated anode; b) assembling the anode, a cathode, a separator and electrolyte into a sealed cell; c) charging the cell to a voltage above that of electrolyte reduction but below that voltage that would violate the anode maximum safe lithium capacity; d) discharging or partially discharging the cell; and e) charging the cell to the full voltage. 
     
     
         12 . A process as in  claim 1 , wherein steps (c) and (d) are repeated and step (c) is repeated at incrementally higher voltages to stimulate further solid electrolyte interphase loss. 
     
     
         13 . A process as in  claim 1 , wherein step (a) comprises applying a reducing current to an anode material bathed in a solution comprising a non-aqueous solvent and at least one dissolved lithium salt in a prelithiation amount P, wherein
     P≧F+E−I   c,      A m =Anode maximum capacity;   F=Formation capacity loss;   E=Elevated temperature age loss; and   
       I c =Irreversible cathode Li +  donation, and the total amount of lithium residing in the anode must be always less than A m . 
     
     
         14 . A process of  claim 13 , wherein the lithium salt is lithium chloride and the solvent is gamma-butyrolactone. 
     
     
         15 . A process as in  claim 7 , wherein step (a) comprises applying a reducing current to an anode material bathed in a solution comprising a non-aqueous solvent and at least one dissolved lithium salt in a prelithiation amount P, wherein
     P≧F+E−I   c,      A m =Anode maximum capacity;   F=Formation capacity loss;   E=Elevated temperature age loss; and   I c =Irreversible cathode Li +  donation, and the total amount of lithium residing in the anode must be always less than A m .   
     
     
         16 . A process of  claim 15 , wherein the lithium salt is lithium chloride and the solvent is gamma-butyrolactone.