Water soluble PAA-based polymer blends as binders for Si dominant anodes

Patent metadata

Field	Value
Publication number	US-11522193-B1
Application number	US-202117344726-A
Country	US
Kind code	B1
Filing date	Jun 10, 2021
Priority date	Jun 10, 2021
Publication date	Dec 6, 2022
Grant date	Dec 6, 2022

Abstract

Systems and methods utilizing water soluble (aqueous) PAA-based polymer binders for silicon-dominant anodes may include an electrode coating layer on a current collector, where the electrode coating layer is formed from silicon and a pyrolyzed water soluble PAA-based polymer blend, wherein the water soluble PAA-based polymer blend comprises PAA and one or more additional water-soluble polymer components. The electrode coating layer may include more than 70% silicon and the anode may be in a lithium ion battery.

First claim

The invention claimed is:

1. A battery electrode, the electrode comprising:
an electrode coating layer on a current collector, the electrode coating layer formed from silicon and a water soluble polyacrylic acid (PAA) based polymer blend, wherein said water soluble PAA-based polymer blend comprises PAA and one or more additional water-soluble polymer components; and wherein the wt % of the PAA is from about 10 wt % to about 15 wt %; and wherein said water soluble PAA-based polymer blend comprises a PAA reacted with a phenolic resin in a ratio of phenolic:PAA of about 1:1 to about 1:5.

2. The electrode according to claim 1 , wherein one or more of said one or more additional water-soluble polymer components comprises a polymer containing one or more functional groups selected from the group consisting of —OH, NH—, NH 2 , and —COOH.

3. The electrode according to claim 1 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA, phenolic resin and a third water-soluble polymer component.

4. The electrode according to claim 1 , wherein the electrode coating layer further comprises conductive additives.

5. The electrode according to claim 1 , wherein the current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer.

6. The electrode according to claim 1 , wherein the electrode coating layer comprises more than 70% silicon.

7. The electrode according to claim 1 , wherein the electrode is in electrical and physical contact with an electrolyte, the electrolyte comprising a liquid, solid, or gel.

8. The electrode according to claim 1 , wherein the battery electrode is in a lithium ion battery.

9. A method of forming an electrode, the method comprising:
creating an electrode coating layer from an electrode slurry comprising an aqueous solution of a water soluble PAA-based polymer blend and Si powder;
fabricating a battery electrode by coating the slurry on a current collector; and
pyrolyzing said electrode coating layer;
wherein said water soluble PAA-based polymer blend comprises PAA and one or more additional water-soluble polymer components; and
wherein the wt % of the PAA is from about 10 wt % to about 15 wt %; and wherein said water soluble PAA-based polymer blend comprises a PAA reacted with a phenolic resin in a ratio of phenolic:PAA of about 1:1 to about 1:5.

10. The method of claim 9 , wherein one or more of said one or more additional water-soluble polymer components comprises a polymer containing one or more functional groups selected from the group consisting of —OH, NH—, NH 2 , and —COOH.

11. The method of claim 9 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA, phenolic resin and a third water-soluble polymer component.

12. The method according to claim 9 , wherein the electrode coating layer further comprises conductive additives.

13. The method according to claim 9 , wherein the current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer.

14. The method according to claim 9 , wherein the electrode coating layer comprises more than 70% silicon.

15. The method according to claim 9 , wherein the electrode is in electrical and physical contact with an electrolyte, the electrolyte comprising a liquid, solid, or gel.

16. A battery, the battery comprising:
a cathode, a separator, an electrolyte, and an anode, the anode comprising an electrode coating layer on a current collector, the electrode coating layer formed from silicon and a pyrolyzed water soluble PAA-based polymer blend, wherein said water soluble PAA-based polymer blend comprises PAA and one or more one or more additional water-soluble polymer components; and wherein the wt % of the PAA is from about 10 wt % to about 15 wt %; and wherein said water soluble PAA-based polymer blend comprises a PAA reacted with a phenolic resin in a ratio of phenolic:PAA of about 1:1 to about 1:5.

17. The battery of claim 16 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA, phenolic resin and a third water-soluble polymer component.

Assignees

• Enevate Corp

Inventors

• Perera Sanjaya D
• Park Benjamin
• Ansari Younes

Classifications

• C09D7/61

  inorganic · CPC title

• C09D5/24 Primary

  Electrically-conducting paints {(conductive materials H01B1/00)} · CPC title

• C08K2003/023

  Silicon · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M4/1395

  of electrodes based on metals, Si or alloys · CPC title