Method and system for a battery electrode having a solvent level to facilitate peeling

Patent metadata

Field	Value
Publication number	US-11588182-B2
Application number	US-202017099155-A
Country	US
Kind code	B2
Filing date	Nov 16, 2020
Priority date	Nov 12, 2019
Publication date	Feb 21, 2023
Grant date	Feb 21, 2023

Abstract

Systems and methods for a battery electrode having a solvent level to facilitate peeling are disclosed. In examples, a battery may include one or more electrodes and an electrolyte. The electrodes include an electrode slurry layer with a solvent. The electrode slurry is coated on a substrate, where the electrode slurry and substrate produce an active material with a residual amount of solvent in response to a heat-treatment, and where the active material comprises 10% to 25% residual solvent by weight following the heat-treatment. The amount of residual solvent facilitates peeling of the active material from the substrate, which, once pyrolyzed, may be used to create a multi-layer film with the current collector film and the active material.

First claim

The invention claimed is:

1. A method of forming a battery, the method comprising:
forming a battery comprising one or more electrodes and an electrolyte, the method of forming an electrode of the one or more electrodes comprising;
mixing an electrode slurry comprising a solvent;
applying the electrode slurry to a removable substrate;
applying a first heat-treatment to the electrode slurry and substrate to produce an active material with a residual amount of solvent, wherein the active material comprises 10% to 25% residual solvent by weight following the heat-treatment; and
laminating the heat-treated active material onto a current collector film.

2. The method according to claim 1 , further comprising:
peeling the removable substrate from the active material; and
applying a second heat treatment to pyrolyze the active material.

3. The method according to claim 1 , further comprising applying a flat press or roll laminating the pyrolyzed active material onto the current collector to form a silicon-composite electrode.

4. The method according to claim 3 , wherein the silicon-composite electrode is an anode, the method further comprising forming a cell by sandwiching a separator and a cathode with the anode.

5. The method according to claim 1 , wherein the solvent is an N-Methyl pyrrolidone (NMP) solvent.

6. The method according to claim 1 , wherein the binder comprises one of a polyimide (PI) or polyamide-imide (PAI) material.

7. The method according to claim 1 , further comprising coating the current collector with a polymeric adhesive layer prior to lamination.

8. The method according to claim 1 , wherein the substrate comprises a polyethylene terephthalate (PET) material.

9. A method of forming a battery, the method comprising:
mixing an electrode slurry comprising a solvent;
applying the electrode slurry to a removable substrate; and
applying a first heat-treatment to the electrode slurry and substrate to produce an active material with 10% to 25% of a residual amount of solvent by weight.

10. The method according to claim 9 , further comprising:
laminating the heat-treated active material onto a current collector film; and
peeling the removable substrate from the active material.

11. The method according to claim 9 , further comprising applying a second heat treatment to pyrolyze the active material.

12. The method according to claim 9 , further comprising applying a flat press or roll laminating the pyrolyzed active material onto the current collector to form a silicon-composite electrode.

13. The method according to claim 12 , wherein the silicon-composite electrode is an anode, the method further comprising forming a cell by sandwiching a separator and a cathode with the anode.

14. The method according to claim 9 , wherein the solvent is an N-Methyl pyrrolidone (NMP) solvent.

15. The method according to claim 9 , wherein the binder comprises one of a polyimide (PI) or polyamide-imide (PAI) material.

16. The method according to claim 9 , further comprising coating the current collector with a polymeric adhesive layer prior to lamination.

17. The method according to claim 9 , wherein the substrate comprises a polyethylene terephthalate (PET) material.

18. A method of forming a battery, the method comprising:
forming a battery comprising one or more electrodes and an electrolyte, the method of forming an electrode of the one or more electrodes comprising;
mixing an electrode slurry comprising a solvent;
applying the electrode slurry to a removable substrate;
applying a first heat-treatment to the electrode slurry and substrate to produce an active material with a residual amount of solvent, wherein the active material comprises 10% to 25% residual solvent by weight following the heat-treatment;
peeling the substrate from the active material; and
laminating the heat-treated active material onto a current collector film to create a multi-layer composite electrode film.

19. The method of claim 18 , further comprising:
applying the multi-layer composite electrode film to a first side of a separator film; and
applying a cathode to a second side of the separator opposite the first side.

Assignees

• Enevate Corp

Inventors

• Chhorng Monika
• Browne Ian

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M4/661

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

• H01M10/0585 Primary

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M4/8896

  Pressing, rolling, calendering (membrane electrode assemblies H01M8/1004) · CPC title

• H01M4/0471

  involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis · CPC title