Methods of coating an electrically conductive substrate and related electrodepositable compositions including graphenic carbon particles

Patent metadata

Field	Value
Publication number	US-2016380255-A1
Application number	US-201615259092-A
Country	US
Kind code	A1
Filing date	Sep 8, 2016
Priority date	Sep 30, 2011
Publication date	Dec 29, 2016
Grant date	—

Abstract

Methods are disclosed in which an electrically conductive substrate is immersed in electrodepositable composition including graphenic carbon particles, the substrate serving as an electrode in an electrical circuit comprising the electrode and a counter-electrode immersed in the composition, a coating being applied onto or over at least a portion of the substrate as electric current is passed between the electrodes. The electrodepositable composition comprises an aqueous medium, an ionic resin, and solid particles including graphenic carbon particles. The solid particles may also include lithium-containing particles.

First claim

We claim:

1 . A method comprising:
immersing an electrically conductive substrate into an electrodepositable composition, the substrate serving as an electrode in an electrical circuit comprising the electrode and a counter-electrode immersed in the composition, a coating being applied onto or over at least a portion of the substrate as electric current is passed between the electrodes, the electrodepositable composition comprising: (a) an aqueous medium; (b) an ionic resin; and (c) solid particles comprising graphenic carbon particles, wherein the composition has a weight ratio of solid particles to ionic resin of at least 4:1.

2 . The method of claim 1 , wherein the graphenic carbon particles comprise thermally produced graphenic carbon particles.

3 . The method of claim 2 , wherein the thermally produced graphenic carbon particles are produced in a thermal zone at a temperature above 3,500° C. and have an average aspect ratio of greater than 3:1.

4 . The method of claim 2 , wherein the thermally produced graphenic carbon particles have a B.E.T. specific surface area of greater than 70 square meters per gram.

5 . The method of claim 2 , wherein at least a portion of the thermally produced graphenic carbon particles comprise curved, curled, creased or buckled sheets.

6 . The method of claim 1 , wherein the composition has a weight ratio of graphenic carbon particles to ionic resin of from 0.1:1 to 2:1.

7 . The method of claim 1 , wherein the ionic resin comprises an anionic resin.

8 . The method of claim 7 , wherein the anionic resin comprises a water soluble base-neutralized, carboxylic acid group-containing resin.

9 . The method of claim 8 , wherein the water soluble resin comprises a cellulose derivative comprising an alkali salt of a carboxymethylcellulose.

10 . The method of claim 1 , wherein the solid particles further comprise lithium-containing particles.

11 . The method of claim 10 , wherein the lithium-containing particles comprise mixed metal oxides comprising Li and at least one element selected from Ni, Co, Fe, Mn, Al and P.

12 . The method of claim 10 , wherein the lithium-containing particles are present in an amount of at least 50 percent by weight, based on the total weight of the solids in the composition.

13 . The method of claim 10 , wherein the relative weight ratio of lithium-containing particles to graphenic carbon particles in the composition is at least 3:1.

14 . The method of claim 1 , wherein the composition has a weight ratio of solid particles to ionic resin of at least 8:1.

15 . The method of claim 1 , wherein the composition has a total solids content of 1 to 5 percent by weight, based on the total weight of the composition.

16 . An electrodepositable composition comprising:
(a) an aqueous medium; (b) an ionic resin; and (c) solid particles comprising:
(i) graphenic carbon particles; and
(ii) lithium-containing particles,
wherein the composition has a weight ratio of solid particles to ionic resin of at least 4:1.

17 . The electrodepositable composition of claim 16 , wherein the graphenic carbon particles comprise thermally produced graphenic carbon particles.

18 . The electrodepositable composition of claim 16 , wherein the composition has a weight ratio of graphenic carbon particles to ionic resin of from 0.1:1 to 2:1.

19 . A lithium ion battery electrode coating electrodeposited on a substrate, the electrodeposited coating comprising:
(a) a cured ionic resin; and (b) solid particles comprising:
(i) graphenic carbon particles; and
(ii) lithium-containing particles,
wherein the coating has a weight ratio of solid particles to cured ionic resin of at least 4:1.

20 . The lithium ion battery electrode coating of claim 19 , wherein the graphenic carbon particles comprise 10 weight percent or less of the total weight of the solid particles.

Assignees

• Ppg Ind Ohio Inc

Inventors

• Daughenbaugh Randy E
• Vanier Noel R
• Hellring Stuart D
• Hung Cheng-Hung

Classifications

• C25D15/00

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

• C25D15/02

  Combined electrolytic and electrophoretic processes {with charged materials} · CPC title

• H01M4/0457 Primary

  from dispersions or suspensions; Electrophoresis · CPC title

• H01M4/13

  Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof · CPC title

• H01M4/625

  Carbon or graphite · CPC title