Electrodes having conformal coatings deposited onto porous electrical current collectors

Patent metadata

Field	Value
Publication number	US-2022209245-A1
Application number	US-202017605299-A
Country	US
Kind code	A1
Filing date	Feb 25, 2020
Priority date	Apr 26, 2019
Publication date	Jun 30, 2022
Grant date	—

Abstract

The present invention is directed towards an electrode comprising a porous electrical current collector comprising a surface comprising a plurality of apertures; a conformal coating present on at least a portion of the surface of the porous electrical current collector, the conformal coating comprising an electrochemically active material and an electrodepositable binder. Also disclosed herein are electrical storage devices comprising the electrode, and methods of preparing electrodes.

First claim

1 . An electrode comprising:
a porous electrical current collector comprising a surface comprising a plurality of apertures; a conformal coating present on at least a portion of the surface of the porous electrical current collector, the conformal coating comprising an electrochemically active material and an electrodepositable binder.

2 . The electrode of claim 1 , wherein the conformal coating is present as a film over the surface of the porous electrical current collector and within the apertures.

3 . The electrode of claim 2 , wherein the film present within the apertures comprises a continuous film that spans the apertures.

4 . The electrode of claim 2 , wherein the thickness of the conformal coating film within the apertures is within 50% of the thickness of the conformal coating film on the surface of the porous electrical current collector.

5 . The electrode of claim 2 , wherein the thickness of the conformal coating on the conductive material and within the apertures is from 0.5 microns to 1,000 microns.

6 . The electrode of claim 1 , wherein the apertures are uniformly distributed over the surface of the porous electrical current collector.

7 . The electrode of claim 1 , wherein the apertures have a diameter of 500 microns or less.

8 . The electrode of claim 1 , wherein the diameter of the apertures is no more than 10 times the thickness of the porous electrical current collector.

9 . The electrode of claim 1 , wherein the apertures have an average longest dimension of 1,000 microns or less.

10 . The electrode of claim 1 , wherein the conformal coating is present as a film over the surface of the porous electrical current collector and does not fill the apertures.

11 . The electrode of claim 1 , wherein the porous electrical current collector comprises aluminum, copper, steel, stainless steel, nickel, conductive carbon, a porous substrate with a conductive coating, or a conductive polymer.

12 . The electrode of claim 1 , wherein the electrodepositable binder comprises a pH-dependent rheology modifier.

13 . The electrode of claim 1 , wherein the electrodepositable binder comprises a fluoropolymer.

14 . The electrode of claim 1 , wherein the electrodepositable binder comprises a non-fluorinated organic film-forming polymer.

15 . The electrode of claim 1 , wherein the electrochemically active material comprises LiCoO 2 , LiNiO 2 , LiFePO 4 , LiFeCoPO 4 , LiCoPO 4 , LiMnO 2 , LiMn 2 O 4 , Li(NiMnCo)O 2 , Li(NiCoAl)O 2 , carbon-coated LiFePO 4 , sulfur, LiO 2 , FeF 2 and FeF 3 , aluminum, SnCo, Fe 3 O 4 , or combinations thereof.

16 . The electrode of claim 1 , wherein the electrochemically active material comprises graphite, lithium titanate, lithium vanadium phosphate, silicon, silicon compounds, tin, tin compounds, sulfur, sulfur compounds, lithium metal, graphene, or a combination thereof.

17 . The electrode of claim 1 , wherein the conformal coating further comprises an electrically conductive agent.

18 . The electrode of claim 1 , wherein the electrodepositable binder comprises a film-forming polymer and a crosslinking agent.

19 . The electrode of claim 1 , wherein the electrode comprises a positive electrode.

20 . The electrode of claim 1 , wherein the electrode comprises a negative electrode.

21 . An electrical storage device comprising:
(a) the electrode of any of claim 1 ; (b) a counter-electrode; and (c) an electrolyte.

22 . The electrical storage device of claim 21 , wherein the electrical storage device comprises a cell, a battery, a battery pack, a secondary battery, a capacitor, and/or a supercapacitor.

23 - 26 . (canceled)

27 . A method of preparing an electrode, the method comprising:
at least partially immersing a porous electrical current collector comprising a surface comprising a plurality of apertures into a bath comprising an electrodepositable coating composition comprising an electrochemically active material and an electrodepositable binder; electrodepositing a conformal coating deposited from the electrodepositable coating onto a portion of the porous electrical current collector immersed in the bath, wherein the conformal coating comprises the electrochemically active material and the electrodepositable binder.

Assignees

• Ppg Ind Ohio Inc

Inventors

• Jones Olivia L
• Hellring Stuart D
• Mohin Jacob W
• Orler Haley L
• Esarey Samuel L

Classifications

• H01G11/28

  arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives · CPC title

• H01M4/0457

  from dispersions or suspensions; Electrophoresis · CPC title

• H01M4/622

  being polymers · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• C25D15/00

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