Calendered cathode compositions and methods of making thereof

Patent metadata

Field	Value
Publication number	US-2025349821-A1
Application number	US-202418835996-A
Country	US
Kind code	A1
Filing date	Feb 2, 2024
Priority date	Feb 3, 2023
Publication date	Nov 13, 2025
Grant date	—

Abstract

Provided herein are compositions and methods for calendering cathode materials for lithium battery construction.

First claim

1 . A bilayer comprising:
a metal substrate having at least two longitudinal edges and at least two transverse edges; at least three lanes of coating material disposed on the metal substrate; wherein a first and a second lane of coating material comprise cathode material; and wherein the longitudinal edges comprise one or more cuts that extend from a longitudinal edge toward the coating material.

2 . The bilayer of claim 1 , wherein the coating material covers at least about 50% of the surface of the metal substrate but does not cover the longitudinal edges.

3 . The bilayer of claim 1 , wherein a third lane of slurry material comprises cathode material.

4 . (canceled)

5 . The bilayer of claim 1 , wherein the three lanes of coating material are identical in composition.

6 . (canceled)

7 . (canceled)

8 . The bilayer of claim 1 , wherein the cuts are periodically spaced.

9 . (canceled)

10 . The bilayer of claim 1 , wherein the cuts are present on both longitudinal edges.

11 . (canceled)

12 . (canceled)

13 . The bilayer of claim 1 , wherein the cuts comprise one or more slits.

14 . The bilayer of claim 13 , wherein the slits comprise an I-shape, an L-shape, a T-shape, or combinations thereof.

15 . (canceled)

16 . (canceled)

17 . The bilayer of claim 1 , wherein the metal substrate has one or more perforations or indentations shaped as one or more battery tabs.

18 . The bilayer of claim 1 , wherein the cathode material has a cathode active material loading of at least 27 mg/cm 2 .

19 . (canceled)

20 . (canceled)

21 . The bilayer of claim 1 , wherein the cathode material porosity is about 25% or less by volume.

22 . (canceled)

23 . (canceled)

24 . (canceled)

25 . The bilayer of claim 1 , wherein the metal substrate is an aluminum foil.

26 . (canceled)

27 . The bilayer of claim 1 , wherein the cathode comprises a cathode active material selected from the group consisting of LiMPO 4 (M=Fe, Ni, Co, Mn); Li x Ti y O z , wherein x is from 0 to 8, y is from 1 to 12, z is from 1 to 24; LiMn 2a NiaO 4 , wherein a is from 0 to 2; a nickel cobalt aluminum oxide; LiNi x Mn y Co z O 2 , x+y+z=1, 0≤x≤1, 0≤y≤1, and 0≤z≤1; and LiNi x Co y Al 2 O 2 , wherein x+y+z=1, and 0≤x≤1, 0≤y≤1, and 0≤z≤1.

28 . The bilayer of claim 27 , wherein the cathode comprises the cathode active material LiNi x Mn y Co z O 2 (NMC), wherein 0≤x≤1, 0≤y≤1, and 0≤z≤1, and wherein x+y+z=1.

29 . (canceled)

30 . (canceled)

31 . A green bilayer comprising:
a metal substrate having at least two longitudinal edges and at least two transverse edges; and a cathode material disposed on the metal substrate; wherein the cathode material covers at least about 50% of the surface of the metal substrate but does not cover the longitudinal edges; and wherein the longitudinal edges comprise one or more cuts that extend from a longitudinal edge toward the cathode material.

32 . The green bilayer of claim 31 , wherein the cuts comprise one or more slits.

33 . The green bilayer of claim 32 , wherein the slits comprise an I-shape, an L-shape, a T-shape, or a combination thereof.

34 . (canceled)

35 . (canceled)

36 . (canceled)

37 . (canceled)

38 . The green bilayer of claim 1 , wherein at least three lanes of coating material are disposed on the metal substrate; and wherein a first and a second lane of coating material comprise cathode material.

39 . A process of making a cathode, comprising:
providing a green bilayer comprising:
a metal substrate having at least two longitudinal edges and at least two transverse edges; and
a cathode material disposed on the metal substrate;
wherein the longitudinal edges comprise one or more cuts that extend from a longitudinal edge to the cathode material disposed on the metal substrate; and

calendering the green bilayer at a temperature of less than 100° C.

40 . (canceled)

41 . (canceled)

42 . (canceled)

43 . (canceled)

44 . (canceled)

45 . (canceled)

46 . (canceled)

47 . (canceled)

48 . The process of claim 1 , further comprising:
cutting the metal substrate; wherein the cutting comprises one or more cuts on longitudinal edges, and wherein the one or more cuts extend from a longitudinal edge to the cathode material disposed on the metal substrate.

49 . (canceled)

50 . (canceled)

Assignees

• Quantumscape Battery Inc

Inventors

• Jokhakar Deep Ashutosh
• Parikh Vihang
• Tokuoka Saori
• Aniagoh William
• Tao Ran
• Narita Yusuke

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M2004/021

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

• H01M2004/028

  Positive electrodes · CPC title

• H01M4/0471

  involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis · CPC title

• H01M4/0435

  Rolling or calendering · CPC title