High-capacity battery electrodes with improved binders, construction, and performance

Patent metadata

Field	Value
Publication number	US-2023015653-A1
Application number	US-202217935789-A
Country	US
Kind code	A1
Filing date	Sep 27, 2022
Priority date	Nov 28, 2016
Publication date	Jan 19, 2023
Grant date	—

Abstract

An anode material composition is provided for a metal-ion battery that comprises an active material coating, a current conductive current collector, and a conductive interlayer coupling the active material coating to the current collector. The active material coating may have a capacity loading of at least 2 mAh/cm2 and comprise active material particles that exhibit volume expansion in the range of about 8 vol. % to about 160 vol. % during a first charge-discharge cycle and volume expansion in the range of about 4 vol. % to about 50 vol. % during one or more subsequent charge-discharge cycles.

First claim

1 . A Li-ion battery anode, comprising:
a current collector; and an electrode layer arranged on the current collector, the electrode layer comprising composite particles and a binder mixed with the composite particles, the binder adhering to the composite particles, the composite particles adhering to the current collector, wherein: the composite particles comprise carbon and silicon and exhibit an average particle size in a range from about 0.2 μm to about 40 μm; the Li-ion battery anode exhibits an average areal capacity loading in a range of about 2 mAh/cm 2 to about 10 mAh/cm 2 ; and the binder comprises a copolymer comprising an acrylamide subunit and a second subunit selected from an acrylic acid, a carboxylic acid, an alginic acid, and a metal salt of any of the foregoing.

2 . The Li-ion battery anode of claim 1 , wherein the electrode layer exhibits a volumetric capacity in a range of about 600 mAh/cc to about 1800 mAh/cc.

3 . The Li-ion battery anode of claim 2 , wherein the volumetric capacity is in a range of about 700 mAh/cc to about 1400 mAh/cc.

4 . The Li-ion battery anode of claim 1 , wherein the composite particles exhibit a specific capacity in a range from about 600 mAh/g to about 2000 mAh/g.

5 . The Li-ion battery anode of claim 1 , wherein the composite particles comprise nanostructured or nano-sized silicon particles.

6 . The Li-ion battery anode of claim 1 , wherein the composite particles comprise carbon coatings.

7 . The Li-ion battery anode of claim 1 , wherein the copolymer is water-soluble.

8 . The Li-ion battery anode of claim 1 , wherein the copolymer is characterized by a molecular weight (MW) of less than about 25,000.

9 . The Li-ion battery anode of claim 1 , wherein the metal is selected from Na, K, Ca, Mg, Li, Sr, Cs, Ba, and La.

10 . The Li-ion battery anode of claim 1 , wherein the copolymer comprises halide anions.

11 . The Li-ion battery anode of claim 1 , wherein the copolymer comprises ammonium cations.

12 . The Li-ion battery anode of claim 1 , wherein the copolymer comprises diallyldimethylammonium chloride (DADMAC), diallyldiethylammonium chloride (DADEAC), methylammonium chloride, N,N-diallyl-N-propylammonium chloride, methylammonium bromide, ethylammonium bromide, propylammonium bromide, butylammonium bromide, methylammonium fluoride, ethylammonium fluoride, propylammonium fluoride, and/or butylammonium fluoride.

13 . The Li-ion battery anode of claim 1 , wherein an amount of the second subunit in the copolymer is less than around 10 wt. %.

14 . The Li-ion battery anode of claim 1 , wherein the electrode layer comprises conductive additive particles.

15 . The Li-ion battery anode of claim 14 , wherein the conductive additive particles comprise carbon.

16 . The Li-ion battery anode of claim 14 , wherein the conductive additive particles are elongated.

17 . The Li-ion battery anode of claim 14 , wherein the conductive additive particles comprise single-walled carbon nanotubes.

18 . The Li-ion battery anode of claim 14 , wherein the electrode layer comprises less than 2 wt. % of the conductive additive particles.

19 . The Li-ion battery anode of claim 1 , wherein the current collector is a metal foil with an average thickness in a range from around 4 μm to around 15 μm.

20 . The Li-ion battery anode of claim 1 , wherein the current collector is an electrodeposited metal foil.

21 . The Li-ion battery anode of claim 1 , wherein the current collector is a copper (Cu) alloy foil comprising less than 99 wt. % copper (Cu).

22 . The Li-ion battery anode of claim 1 , additionally comprising a conductive interlayer between the current collector and the electrode layer.

23 . The Li-ion battery anode of claim 22 , wherein:
the binder of the electrode layer is a first binder; the conductive interlayer comprises a second binder; and the second binder comprises the copolymer.

24 . The Li-ion battery anode of claim 22 , wherein:
the binder of the electrode layer is a first binder; the conductive interlayer comprises a second binder; and the second binder comprises a poly(vinyl alcohol).

25 . The Li-ion battery anode of claim 22 , wherein:
the binder of the electrode layer is a first binder; the conductive interlayer comprises a second binder; and the second binder comprises a second copolymer comprising a second acrylamide subunit and a third subunit selected from a second acrylic acid, a second carboxylic acid, a second alginic acid, and a second metal salt of any of the foregoing.

26 . The Li-ion battery anode of claim 22 , wherein the conductive interlayer comprises elongated conductive particles.

27 . The Li-ion battery anode of claim 26 , wherein the elongated conductive particles comprise single-walled carbon nanotubes.

28 . A Li-ion battery comprising:
the Li-ion battery anode of claim 1 ; a cathode; a separator interposed between the Li-ion battery anode and the cathode; and an electrolyte impregnating the separator, wherein: the composite particles exhibit volume expansion in a range of about 8 vol. % to about 160 vol. % during a first charge-discharge cycle and volume expansion in a range of about 4 vol. % to about 50 vol. % during one or more subsequent charge-discharge cycles.

29 . The Li-ion battery of claim 28 , wherein:
the Li-ion battery exhibits a specific capacity in a range from about 500 mAh/g to about 3000 mAh/g.

Assignees

• Sila Nanotechnologies Inc

Inventors

• Yushin Gleb
• Kajdos Adam
• Gerber Laura
• Steiger Jens
• Yen Justin
• Doane Justin
• Jacobs Alexander
• Hantsoo Eerik
• Berdichevsky Eugene

Classifications

• H01M10/0587

  of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators · CPC title

• H01M10/0525

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

• H01M2004/027

  Negative electrodes · CPC title

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• H01M4/134 Primary

  Electrodes based on metals, Si or alloys · CPC title