Solid film as binder for battery electrodes

Patent metadata

Field	Value
Publication number	US-2019181431-A1
Application number	US-201815994977-A
Country	US
Kind code	A1
Filing date	May 31, 2018
Priority date	Dec 7, 2017
Publication date	Jun 13, 2019
Grant date	—

Abstract

In various embodiments, a method of forming an electrode includes providing a current collector, providing a substantially solid layer of electrode attachment substance on a side of the current collector, providing electrochemically active material adjacent the substantially solid layer of the electrode attachment substance, and adhering the electrochemically active material to the side of the current collector via the electrode attachment substance. In some examples, the electrochemically active material is provided in powder form. In some examples, the electrochemically active material is provided between the substantially solid layer of electrode attachment substance and the current collector.

First claim

1 .- 35 . (canceled)

36 . A method of forming an electrode, the method comprising:
providing a current collector; providing a layer comprising electrochemically active material on a side of the current collector; providing a substantially solid layer of electrode attachment substance adjacent the layer comprising electrochemically active material such that the electrochemically active material is between the substantially solid layer of electrode attachment substance and the current collector; and adhering the electrochemically active material to the side of the current collector via the electrode attachment substance.

37 . The method of claim 36 , further comprising providing a second substantially solid layer of electrode attachment substance between the layer comprising electrochemically active material and the current collector such that the electrochemically active material is sandwiched between both of the provided layers of electrode attachment substance.

38 . The method of claim 36 , wherein the electrochemically active material is provided in powder form.

39 . The method of claim 36 , wherein the electrochemically active material is provided as a film.

40 . The method of claim 39 , wherein the film comprises a silicon carbon composite film.

41 . The method of claim 36 , wherein the electrochemically active material comprises at least about 50% to about 100% by weight of silicon.

42 . The method of claim 41 , wherein the electrochemically active material comprises the silicon at about 60% to about 100% by weight.

43 . The method of claim 42 , wherein the electrochemically active material comprises the silicon at about 70% to about 100% by weight.

44 . The method of claim 43 , wherein the electrochemically active material comprises the silicon at about 80% to about 100% by weight.

45 . The method of claim 36 , wherein the layer of electrode attachment substance comprises a thermoplastic film.

46 . The method of claim 36 , wherein the layer of electrode attachment substance is insoluble in solvent at a temperature below about 200° C.

47 . The method of claim 36 , wherein the layer of electrode attachment substance comprises a polyphenylene sulfide film, a polyether ether ketone film, a polyether sulfone film, a polysulfone film, or a polyethylene terephthalate film.

48 . The method of claim 36 , wherein adhering comprises applying pressure to the electrode attachment substance and/or the electrochemically active material to adhere the electrochemically active material to the current collector.

49 . The method of claim 36 , wherein adhering comprises applying heat to the electrode attachment substance and/or the electrochemically active material to adhere the electrochemically active material to the current collector.

50 . The method of claim 36 , wherein adhering comprises an extrusion process.

51 . The method of claim 36 , wherein the current collector is provided in roll form.

52 . The method of claim 36 , wherein the layer of electrode attachment substance is provided in roll form.

53 . The method of claim 36 , wherein the layer comprising electrochemically active material is provided in roll form.

54 . The method of claim 36 , wherein the method comprises a roll to roll process.

55 . The method of claim 36 , further comprising:
providing a layer comprising a second electrochemically active material on a second side of the current collector; providing a substantially solid layer of a second electrode attachment substance adjacent the layer comprising the second electrochemically active material such that the second electrochemically active material is between the second electrode attachment substance and the current collector; and adhering the second electrochemically active material to the second side of the current collector via the second electrode attachment substance.

56 . The method of claim 55 , further comprising providing a substantially solid layer of a third electrode attachment substance between the layer comprising the second electrochemically active material and the current collector such that the second electrochemically active material is sandwiched between the second and third electrode attachment substance.

57 . The method of claim 55 , wherein the second electrochemically active material is provided in powder form.

58 . The method of claim 55 , wherein the second electrochemically active material is provided as a film.

59 . The method of claim 55 , wherein the second electrochemically active material comprises a silicon carbon composite film.

60 . The method of claim 55 , wherein the second electrochemically active material comprises at least about 50% to about 100% by weight of silicon.

61 . The method of claim 60 , wherein the second electrochemically active material comprises the silicon at about 60% to about 100% by weight.

62 . The method of claim 61 , wherein the second electrochemically active material comprises the silicon at about 70% to about 100% by weight.

63 . The method of claim 62 , wherein the second electrochemically active material comprises the silicon at about 80% to about 100% by weight

64 . The method of claim 55 , wherein the second electrode attachment substance comprises a thermoplastic film.

65 . The method of claim 55 , wherein the second electrode attachment substance comprises a different material than the electrode attachment substance.

66 . The method of claim 55 , wherein adhering the electrochemically active material and adhering the second electrochemically active material occur simultaneously.

67 . The method of claim 55 , wherein the electrode is a negative electrode.

Assignees

• Enevate Corp

Inventors

• Canton Giulia

Classifications

• H01M4/1395 Primary

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

• H01M4/134

  Electrodes based on metals, Si or alloys · CPC title

• H01M4/661

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

• H01M2004/027

  Negative electrodes · CPC title

• H01M10/0525

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