Method of coating an electrical current collector and electrodes resulting therefrom

Patent metadata

Field	Value
Publication number	US-11482696-B2
Application number	US-202016801507-A
Country	US
Kind code	B2
Filing date	Feb 26, 2020
Priority date	Feb 26, 2020
Publication date	Oct 25, 2022
Grant date	Oct 25, 2022

Abstract

The present invention is directed to a method of coating an electrical current collector comprising treating a portion of a surface of the electrical current collector with an adhesion promoting composition to deposit a treatment layer over the portion of the surface of the electrical current collector, wherein the resulting surface of the electrical current collector comprises (a) a treated portion comprising the treatment layer and (b) a non-treated portion that lacks the treatment layer; electrodepositing an electrodeposited coating layer from an electrodepositable coating composition onto the surface of the electrical current collector to form a coated electrical current collector; and rinsing the coated electrical current collector, wherein the electrodeposited coating layer substantially adheres to the treated portion of the surface and does not adhere to the non-treated portion of the surface. Also disclosed are electrodes and electrical storage devices.

First claim

What is claimed is:

1. A method of coating an electrical current collector comprising:
treating a portion of a surface of the electrical current collector with an adhesion promoting composition to deposit a treatment layer over the portion of the surface of the electrical current collector, wherein the resulting surface of the electrical current collector comprises (a) a treated portion comprising the treatment layer and (b) a non-treated portion that lacks the treatment layer;
electrodepositing an electrodeposited coating layer from an electrodepositable coating composition onto the surface of the electrical current collector to form a coated electrical current collector; and
rinsing the coated electrical current collector, wherein the electrodeposited coating layer substantially adheres to the treated portion of the surface and does not adhere to the non-treated portion of the surface.

2. The method of coating an electrical current collector of claim 1 , wherein the electrical current collector comprises aluminum, copper, steel, stainless steel, nickel, or combinations thereof.

3. The method of coating an electrical current collector of claim 1 , wherein the adhesion promoting composition comprises a conductive primer coating composition, and the treatment layer comprises a conductive primer coating layer.

4. The method of coating an electrical current collector of claim 3 , wherein the conductive primer coating composition comprises a carbon-based conductive primer coating composition, and the conductive primer coating layer comprises a carbon-based conductive primer coating layer.

5. The method of coating an electrical current collector of claim 1 , wherein the adhesion promoting composition comprises a pretreatment composition, and the treatment layer comprises a pretreatment layer.

6. The method of coating an electrical current collector of claim 1 , wherein electrodepositing the electrodeposited coating layer comprises:
at least partially immersing the electrical current collector into a bath comprising the electrodepositable coating composition; and
electrodepositing a coating deposited from the electrodepositable coating onto at least a portion of the surface of the electrical current collector immersed in the bath.

7. The method of coating an electrical current collector of claim 1 , wherein the electrodepositable coating composition comprises an electrochemically active material and an electrodepositable binder comprising a pH-dependent rheology modifier, and the electrodeposited coating layer comprises the electrochemically active material and the electrodepositable binder.

8. The method of coating an electrical current collector of claim 7 , wherein the electrodepositable binder further comprises a fluoropolymer, a non-fluorinated organic film-forming polymer, a dispersant, or combinations thereof.

9. The method of coating an electrical current collector of claim 7 , wherein the electrodepositable binder further comprises a crosslinking agent.

10. The method of coating an electrical current collector of claim 7 , wherein the electrochemically active material comprises LiCoO 2 , LiNiO 2 , LiFePO 4 , LiFeCoPO 4 , LiCoPO 4 , LiMnO 2 , LiMn 2 O 4 , Li(NiMnCo)O 2 , Li(NiCoAl)O 2 , carbon-coated LiFePO 4 , sulfur, sulfur compounds, LiO 2 , FeF 2 and FeF 3 , aluminum, SnCo, Fe 3 O 4 , or combinations thereof.

11. The method of coating an electrical current collector of claim 7 , wherein the electrochemically active material comprises graphite, lithium titanate, lithium vanadium phosphate, silicon, silicon compounds, tin, tin compounds, lithium metal, graphene, or a combination thereof.

12. The method of coating an electrical current collector of claim 7 , wherein the electrodepositable coating composition further comprises an electrically conductive agent.

13. An electrode comprising:
an electrical current collector having a surface;
a treatment layer on a portion of the surface of the electrical current collector, wherein (a) a portion of the surface of the electrical current collector comprises the treatment layer and (b) a portion of the surface of the electrical current collector lacks the treatment layer; and
an electrodeposited coating layer that is present over the treatment layer and is not present over the portion of the surface of the electrical current collector lacks the treatment layer.

14. The electrode of claim 13 , wherein the non-treated portion of the surface of the electrical current collector is substantially free of the electrodeposited coating layer.

15. The electrode of claim 13 , wherein the electrode is produced by the method of coating an electrical current collector of claim 1 .

16. The electrode of claim 13 , wherein the combined thickness of the treatment layer and electrodeposited coating layer is from 0.5 microns to 1,000 microns.

17. The electrode of claim 13 , wherein the treatment layer and electrodeposited coating layer form a sloped edge having an angle measured from the surface of the electrical current collector of at least 35°, as measured by the EDGE ANGLE MEASUREMENT TEST METHOD.

18. The electrode of claim 13 , wherein an edge of the treatment layer and electrodeposited coating layer is sloped and the ratio of the length of the slope to the thickness of the treatment layer and electrodeposited coating layer of the slope is at least 0.5:1, as measured by the EDGE ANGLE MEASUREMENT TEST METHOD.

19. The electrode of claim 13 , wherein the electrodeposited coating layer comprises LFP and an edge of the treatment layer and electrodeposited coating layer is sloped and the ratio of the length of the slope to the thickness of the treatment layer and electrodeposited coating layer of the slope is from 0.5:1 to 2.4:1, as measured by the EDGE ANGLE MEASUREMENT TEST METHOD.

20. The electrode of claim 13 , wherein the electrodeposited coating layer comprises NMC and an edge of the electrodeposited coating layer is sloped and the ratio of the length of the slope to the thickness of the treatment layer and electrodeposited coating layer of the slope is from 0.7:1 to 1.4:1, as measured by the EDGE ANGLE MEASUREMENT TEST METHOD.

21. The electrode of claim 13 , wherein the electrical current collector comprises aluminum, copper, steel, stainless steel, nickel, or combinations thereof.

22. The electrode of claim 13 , wherein the electrodeposited coating layer comprises an electrochemically active material and an electrodepositable binder comprising a pH-dependent rheology modifier.

23. The electrode of claim 22 , wherein the electrodepositable binder further comprises a fluoropolymer, a non-fluorinated organic film-forming polymer, a dispersant, or combinations thereof.

24. The electrode of claim 22 , wherein the electrodepositable binder further comprises a crosslinking agent.

25. The electrode of claim 19 , wherein the electrodeposited coating layer further comprises an electrically conductive agent.

26. The electrode of claim 13 , wherein the electrodeposited coating layer is crosslinked.

27. The electrode of claim 13 , wherein the electrode comprises a positive electrode.

28. The electrode of claim 13 , wherein the electrode comprises a negative electrode.

29. An electrical storage device comprising:
(a) electrode of claim 13 ;
(b) a counter-electrode; and
(c) an electrolyte.

30.

Assignees

• Ppg Ind Ohio Inc

Inventors

• Oakes Landon J
• Orler Haley L
• Furar Elizabeth A
• Hellring Stuart D

Classifications

• H01M4/661

  Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence) · CPC title

• H01M4/623

  fluorinated polymers · CPC title

• H01M4/0404 Primary

  by coating on electrode collectors · CPC title

• C25D15/00

  Electrolytic or electrophoretic production of coatings containing embedded materials, e.g. particles, whiskers, wires · CPC title

• H01M4/669

  Steels · CPC title