Dry energy storage device electrode and methods of making the same

Patent metadata

Field	Value
Publication number	US-12406995-B2
Application number	US-202318528614-A
Country	US
Kind code	B2
Filing date	Dec 4, 2023
Priority date	Apr 18, 2014
Publication date	Sep 2, 2025
Grant date	Sep 2, 2025

Abstract

An energy storage device can include a cathode and an anode, where at least one of the cathode and the anode are made of a polytetrafluoroethylene (PTFE) composite binder material including PTFE and at least one of polyvinylidene fluoride (PVDF), a PVDF co-polymer, and poly(ethylene oxide) (PEO). The energy storage device can be a lithium ion battery, a lithium ion capacitor, and/or any other lithium based energy storage device. The PTFE composite binder material can have a ratio of about 1:1 of PTFE to a non-PTFE component, such a PVDF, PVDF co-polymer and/or PEO.

First claim

What is claimed is:

1. A method of fabricating a cathode of an energy storage device, comprising:
combining a first portion of a porous carbon material and at least one component of a composite binder material to form a first mixture, wherein the at least one component comprises at least one of polyvinylidene fluoride (PVDF), a PVDF co-polymer, and poly(ethylene oxide) (PEO);
subjecting the first mixture to a high shear process; and
adding polytetrafluoroethylene (PTFE) to the first mixture after the subjecting step to form a second mixture.

2. The method of claim 1 , further comprising adding at least one of an active material of the cathode, a second portion of the porous carbon material and a conductive carbon additive to the first mixture after the subjecting step.

3. The method of claim 2 , wherein the active material comprises a lithium metal oxide.

4. The method of claim 2 , wherein the active material comprises lithium nickel manganese cobalt oxide, lithium manganese oxide, lithium iron phosphate, lithium cobalt oxide, or lithium nickel cobalt aluminum oxide.

5. The method of claim 1 , wherein the porous carbon material comprises activated carbon.

6. The method of claim 1 , wherein the at least one component comprises PVDF.

7. The method of claim 1 , wherein combining comprises combining the first portion of the porous carbon material and the at least one component of the composite binder material at a mass ratio of 1:1 to 5:1.

8. The method of claim 1 , wherein a mass ratio of PTFE to the at least one component of the composite binder material is 1:5 to 5:1.

9. The method of claim 1 , wherein the high shear process comprises jet-milling.

10. The method of claim 1 , wherein the method is a dry fabrication process.

11. The method of claim 1 , further comprising calendering the second mixture to form a free-standing cathode film.

12. A method of fabricating an energy storage device, comprising:
disposing the cathode film of claim 11 over a current collector to form a cathode; and
inserting an anode, the cathode and a separator within a housing, wherein the separator is positioned between the anode and the cathode.

13. The method of claim 12 , wherein the energy storage device is a lithium ion battery or a lithium ion capacitor.

14. A method of fabricating a cathode of an energy storage device, comprising:
combining a first portion of a porous carbon material and at least one component of a composite binder material to form a first mixture, wherein the at least one component comprises at least one of polyvinylidene fluoride (PVDF), a PVDF co-polymer, and poly(ethylene oxide) (PEO);
subjecting the first mixture to a high shear process; and
adding an active material of the cathode to the first mixture after the subjecting step to form a second mixture.

15. The method of claim 14 , further comprising adding polytetrafluoroethylene (PTFE) to the first mixture after the subjecting step.

16. The method of claim 15 , wherein a mass ratio of PTFE to the at least one component of the composite binder material is 1:5 to 5:1.

17. The method of claim 14 , further comprising adding at least one of a second portion of the porous carbon material and a conductive carbon additive to the first mixture after the subjecting step.

18. The method of claim 14 , wherein combining comprises combining the first portion of the porous carbon material and the at least one component of the composite binder material at a mass ratio of 1:1 to 5:1.

19. The method of claim 14 , wherein the high shear process comprises jet-milling.

20. The method of claim 14 , wherein the method is a dry fabrication process.

Assignees

• Tesla Inc

Inventors

• Duong Hieu Minh
• Feigenbaum Haim
• Hong Jian

Classifications

• H01M10/0525 Primary

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M4/625

  Carbon or graphite · CPC title

• H01M4/0435

  Rolling or calendering · CPC title

• H01G9/15 Primary

  Solid electrolytic capacitors (H01G11/00 takes precedence) · CPC title

• H01G9/0425

  specially adapted for cathode · CPC title