Multi-layer battery electrode design for enabling thicker electrode fabrication

Patent metadata

Field	Value
Publication number	US-2016013480-A1
Application number	US-201414771126-A
Country	US
Kind code	A1
Filing date	Mar 5, 2014
Priority date	Mar 15, 2013
Publication date	Jan 14, 2016
Grant date	—

Abstract

Implementations of the present invention relate generally to high-capacity energy storage devices and methods and apparatus for fabricating high-capacity energy storage devices. In one implementation, a method for forming a multi-layer cathode structure is provided. The method comprises providing a conductive substrate, depositing a first slurry mixture comprising a cathodically active material to form a first cathode material layer over the conductive substrate, depositing a second slurry mixture comprising a cathodically active material to form a second cathode material layer over the first cathode material layer, and compressing the as-deposited first cathode material layer and the second cathode material layer to achieve a desired porosity.

First claim

1 . A method for forming a multi-layer cathode structure, comprising:
providing a conductive substrate; depositing a first slurry mixture comprising a cathodically active material to form a first cathode material layer over the conductive substrate; depositing a second slurry mixture comprising a cathodically active material to form a second cathode material layer over the first cathode material layer; and compressing the as-deposited first cathode material layer and the second cathode material layer to achieve a desired porosity.

2 . The method of claim 1 , wherein the first slurry mixture and the second slurry mixture each independently comprise:
a cathodically active material; and at least one of a binding agent, a binding precursors, an electro-conductive material and a solvent.

3 . The method of claim 1 , wherein a solids content of the first slurry mixture is different than a solids content of the second slurry mixture.

4 . The method of claim 2 , wherein a tap density of the cathodically active material of the first slurry mixture differs from a tap density of the cathodically active material of the second slurry mixture.

5 . The method of claim 4 , wherein the cathodically active material of the first slurry mixture differs from the cathodically active material of the second slurry mixture.

6 . The method of claim 4 , wherein the wt. % of binding agent in the first slurry mixture differs from the wt. % of binding agent in the second slurry mixture.

7 . The method of claim 4 , wherein the particle size distribution of the first slurry mixture differs from the particle size distribution of the second slurry mixture.

8 . The method of claim 7 , wherein the particle size distribution of the first slurry mixture and the particle size distribution of the second slurry mixture are each independently selected from uni-modal particle size distribution, bi-modal particle size distribution, and multi-modal particle size distribution.

9 . The method of claim 4 , wherein compressing the as-deposited first cathode material layer and the second cathode material layer to achieve a desired porosity comprises calendering the as-deposited layers.

10 . The method of claim 4 , wherein the conductive substrate comprises aluminum.

11 . The method of claim 4 , wherein the cathodically active material of the first slurry mixture and the cathodically active material of the second slurry mixture are each independently selected from the group comprising: lithium cobalt dioxide (LiCoO 2 ), lithium manganese dioxide (LiMnO 2 ), titanium disulfide (TiS 2 ), LiNixCo 1-2x MnO 2 , LiMn 2 O 4 , LiFePO 4 , LiFe 1-x MgPO 4 , LiMoPO 4 , LiCoPO 4 , Li 3 V 2 (PO 4 ) 3 , LiVOPO 4 , LiMP 2 O 7 , LiFe 1.5 P 2 O 7 , LiVPO 4 F, LiAlPO 4 F, Li 5 V(PO 4 ) 2 F 2 , Li 5 Cr(PO 4 ) 2 F 2 , Li 2 CoPO 4 F, Li 2 NiPO 4 F, Na 5 V 2 (PO 4 ) 2 F 3 , Li 2 FeSiO 4 , Li 2 MnSiO 4 , Li 2 VOSiO 4 , LiNiO 2 , and combinations thereof.

12 . The method of claim 4 , wherein the binding agent is selected from the group comprising: polyvinylidene fluoride (PVDF), styrene butadiene rubber (SBR), carboxymethylcellulose (CMC), and combinations thereof.

13 . The method of claim 4 , wherein the cathodically active material of the first slurry mixture comprises particles having a first average diameter and the cathodically active material of the second slurry mixture comprises particles having a second average diameter, wherein the second average diameter is greater than the first average diameter.

14 . The method of claim 13 , wherein the first average diameter is between about 2 μm and about 15 μm and the second average diameter is between about 5 μm and about 15 μm.

15 . The method of claim 13 , wherein the second average diameter is between about 2 μm and about 15 μm and the first average diameter is between about 5 μm and about 15 μm.

Assignees

• Applied Materials Inc

Inventors

• Sikha Godfrey
• Herle Subramanya P
• Wang Connie P
• Wang Zheng
• Zeng Dongli
• Wang Fei C
• Orilall Mahendra C

Classifications

• H01M2004/028

  Positive electrodes · CPC title

• H01M4/0404 Primary

  by coating on electrode collectors · CPC title

• H01M4/366 Primary

  as layered products · CPC title

• H01M4/0409

  by a doctor blade method, slip-casting or roller coating · CPC title

• H01M4/1391

  of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx · CPC title