Lco electrodes and batteries fabricated therefrom

Abstract

Electrodes for batteries, active stacks for batteries, batteries and methods of fabrication are described where the electrode has an LiCoO2 (LCO) electrode layer with a (110), (101), (104), or (003) crystallographic orientation or combinations thereof.

What is claimed is: 
     
         1 . An electrode for a battery, the electrode comprising:
 a LiCoO 2  (LCO) electrode layer having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003).   
     
     
         2 . The electrode of  claim 1 , wherein the electrode is a component of a battery. 
     
     
         3 . In a battery having an electrode layer, an improvement comprising:
 a LiCoO 2  (LCO) electrode layer having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003).   
     
     
         4 . An electrode for a battery, the electrode comprising:
 a LiCoO 2  (LCO) electrode layer having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003);   the electrode layer comprising a material having one or more following properties:   (i) a high density;   (ii) a thickness from less than about 1 μm to about 200 μm or greater;   (iii) at least one smooth surface; and   (iv) surfaces with continuous grains between the surfaces that create conductive pathways between the surfaces.   
     
     
         5 . The electrode of  claim 4 , wherein the electrode is a component of a battery. 
     
     
         6 . In a battery having an electrode layer, an improvement comprising:
 a LiCoO 2  (LCO) electrode layer having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003);   the electrode layer comprising a material having one or more following properties:   a high density;   (ii) a thickness from less than about 1 μm to about 200 μm or greater;   (iii) at least one smooth surface; and   (iv) surfaces with continuous grains between the surfaces that create conductive pathways between the surfaces.   
     
     
         7 . An electrode for a battery, the electrode comprising:
 a fully dense LiCoO 2  (LCO) electrode layer;   said electrode layer having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003).   
     
     
         8 . The electrode of  claim 7 , wherein the electrode is a component of a battery. 
     
     
         9 . In a battery having an electrode layer, an improvement comprising:
 a fully dense LiCoO 2  (LCO) electrode layer;   said electrode layer having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003).   
     
     
         10 . An electrode for a battery, the electrode comprising:
 a layer of fully dense LiCoO 2  (LCO) material;   said layer of LiCoO 2  (LCO) material having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003).   
     
     
         11 . The electrode of  claim 10 , wherein the electrode is a component of a battery. 
     
     
         12 . In a battery having an electrode layer, an improvement comprising:
 a layer of fully dense LiCoO 2  (LCO) material;   said layer of LiCoO 2  (LCO) material having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003).   
     
     
         13 . An electrode for a battery, the electrode comprising:
 a fully dense LiCoO 2  (LCO) electrode layer;   said electrode layer having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003);   said electrode layer having a thickness from less than about 1 μm to about 200 μm or greater;   said electrode layer having at least one smooth surface;   said electrode layer having surfaces with continuous grains between the surfaces that create conductive pathways between the surfaces.   
     
     
         14 . The electrode of  claim 13 , wherein the electrode is a component of a battery. 
     
     
         15 . In a battery having an electrode layer, an improvement comprising:
 a fully dense LiCoO 2  (LCO) electrode layer;   said electrode layer having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003);   said electrode layer having a thickness from less than about 1 μm to about 200 μm or greater;   said electrode layer having at least one smooth surface;   said electrode layer having surfaces with continuous grains between the surfaces that create conductive pathways between the surfaces.   
     
     
         16 . An electrode for a battery, the electrode comprising:
 an electrode layer of fully dense LiCoO 2  (LCO) material;   said electrode layer of LiCoO 2  (LCO) material having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003);   said electrode layer having a thickness from less than about 1 μm to about 200 μm or greater;   said electrode layer having at least one smooth surface;   said electrode layer having surfaces with continuous grains between the surfaces that create conductive pathways between the surfaces.   
     
     
         17 . The electrode of  claim 16 , wherein the electrode is a component of a battery. 
     
     
         18 . In a battery having an electrode layer, an improvement comprising:
 an electrode layer of fully dense LiCoO 2  (LCO) material;   said electrode layer of LiCoO 2  (LCO) material having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003);   said electrode layer having a thickness from less than about 1 μm to about 200 μm or greater;   said electrode layer having at least one smooth surface;   said electrode layer having surfaces with continuous grains between the surfaces that create conductive pathways between the surfaces.   
     
     
         19 . An active stack for a battery, the active stack comprising:
 an anode layer;   a cathode layer; and   an electrolyte layer between the anode layer and the cathode layer;   wherein the cathode layer comprises a layer of fully dense LiCoO 2  (LCO) material; and   wherein the LiCoO 2  (LCO) material has a crystal orientation selected from the group consisting of (110); (101); (104); and (003).   
     
     
         20 . The active stack of  claim 19 :
 wherein the electrolyte layer comprises a solid-state electrolyte layer; and   wherein the layer of LiCoO 2  (LCO) material has a smooth surface facing the electrolyte layer.   
     
     
         21 . The active stack of  claim 19 , wherein the anode layer comprises a layer of lithium-ion based active material. 
     
     
         22 . An active stack for a battery, the active stack comprising:
 an anode layer;   a cathode layer; and   an electrolyte layer between the anode layer and the cathode layer;   said cathode layer comprising a layer of fully dense LiCoO 2  (LCO) material;   said LiCoO 2  (LCO) material having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003);   said cathode layer having a thickness from less than about 1 μm to about 200 μm or greater;   said cathode layer having at least one smooth surface;   said cathode layer having surfaces with continuous grains between the surfaces that create conductive pathways between the surfaces.   
     
     
         23 . The active stack of  claim 22 :
 wherein the electrolyte layer comprises a solid-state electrolyte layer; and   wherein the layer of LiCoO 2  (LCO) material has a smooth surface facing the electrolyte layer.   
     
     
         24 . The active stack of  claim 22 , wherein the anode layer comprises a layer of lithium-ion based active material. 
     
     
         25 . A battery, comprising:
 a first current collector;   an anode layer adjacent the first current collector;   an electrolyte layer adjacent the anode layer;   a cathode layer adjacent the electrolyte layer; and   a second current collector adjacent the cathode layer;   wherein the cathode layer comprises a layer of fully dense LiCoO 2  (LCO) material; and   wherein the LiCoO 2  (LCO) material has a crystal orientation selected from the group consisting of: (110); (101); (104); and (003).   
     
     
         26 . The battery of  claim 25 :
 wherein the electrolyte layer comprises a solid-state electrolyte layer; and   wherein the layer of LiCoO 2  (LCO) material has a smooth surface facing the electrolyte layer.   
     
     
         27 . The battery of  claim 25 , wherein the anode layer comprises a layer of lithium-ion based active material. 
     
     
         28 . The battery of  claim 25 , wherein the first current collector comprises a copper-based material. 
     
     
         29 . The battery of  claim 25 , wherein the second current collector comprises an aluminum-based material. 
     
     
         30 . A battery, comprising:
 a first current collector;   an anode layer adjacent the first current collector;   an electrolyte layer adjacent the anode layer;   a cathode layer adjacent the electrolyte layer; and   a second current collector adjacent the cathode layer;   said cathode layer comprising a layer of fully dense LiCoO 2  (LCO) material; and   said LiCoO 2  (LCO) material having a crystal orientation selected from the group consisting of: (110); (101); (104); and (003);   said cathode layer having a thickness from less than about 1 μm to about 200 μm or greater;   said cathode layer having at least one smooth surface;   said cathode layer having surfaces with continuous grains between the surfaces that create conductive pathways between the surfaces.   
     
     
         31 . The battery of  claim 30 :
 wherein the electrolyte layer comprises a solid-state electrolyte layer; and   wherein the layer of LiCoO 2  (LCO) material has a smooth surface facing the electrolyte layer.   
     
     
         32 . The battery of  claim 30 , wherein the anode layer comprises a layer of lithium-ion based active material. 
     
     
         33 . The battery of  claim 30 , wherein the first current collector comprises a copper-based material. 
     
     
         34 . The battery of  claim 30 , wherein the second current collector comprises an aluminum-based material. 
     
     
         35 . A method of forming an electrode material, comprising:
 forming a mixture of LiOH and KOH;   forming a melt by heating the mixture of LiOH and KOH;   adding CoO and dissolving the CoO in the melt; and   inserting an aluminum substrate into the melt and electroplating LiCoO 2  onto the aluminum substrate with a crystallographic orientation selected from the group consisting of: (110); (101); (104); and (003);   wherein the crystallographic orientation is a function of the electroplating.   
     
     
         36 . The method of  claim 35 , wherein the mixture of LiOH and KOH comprises about 8 g KOH and about 0.75 g LiOH. 
     
     
         37 . The method of  claim 36 , further comprising:
 heating the mixture of LiOH and KOH to about 350° C.; and   adding about 0.5 g CoO to the mixture.   
     
     
         38 . The method of  claim 35 , further comprising forming (003) oriented LiCoO 2  by applying a low constant current density of about 1 mA/cm 2  between a working electrode and a counter electrode. 
     
     
         39 . The method of  claim 35 , further comprising forming (001) oriented LiCoO 2  by applying about 30 mA/cm 2  pulses between a working electrode and a counter electrode for about 2 seconds with about 5 seconds rest between pulses. 
     
     
         40 . The method of  claim 35 , further comprising forming polycrystalline (110), (001) oriented LiCoO 2  by applying about 20 mA/cm 2  pulses between a working electrode and a counter electrode for about 5 seconds with about 5 seconds rest between pulses. 
     
     
         41 . The method of  claim 35 , further comprising forming (110) oriented LiCoO 2  by applying about 20 mA/cm 2  pulses between a working electrode and a counter electrode for about 2 seconds with about 5 seconds rest between pulses.