Electrode having a selectively loaded matrix and method of manufacturing

Patent metadata

Field	Value
Publication number	US-9780362-B2
Application number	US-201514928362-A
Country	US
Kind code	B2
Filing date	Oct 30, 2015
Priority date	Oct 30, 2015
Publication date	Oct 3, 2017
Grant date	Oct 3, 2017

Abstract

Electrodes made with a matrix selectively loaded with particular active particles provide uniform distribution and reduce issues due to particle expansion. The electrode has a current collector, a separator and a matrix having first pores having a first size and second pores having a second size, the first size being larger than the second size, the second pores being uniformly distributed throughout the matrix; first active particles deposited in the first pores, the first active particles having a first particle size smaller than the first pores and larger than the second pores; and second active particles deposited in the second pores, the second active particles having a second particle size smaller than the second pores.

First claim

What is claimed is:

1. An electrode having a current collector and a separator, the electrode comprising:
a matrix having first pores having a first size and second pores having a second size, the first size being larger than the second size, the second pores being uniformly distributed throughout the matrix;
first active particles deposited in the first pores, the first active particles having a first particle size smaller than the first pores and larger than the second pores; and
second active particles deposited in the second pores, the second active particles having a second particle size smaller than the second pores;
wherein the matrix is a metal foam.

2. The electrode of claim 1 , wherein the first active particles are graphite and the second active particles are silicon.

3. The electrode of claim 1 , wherein the matrix, the first active particles and the second active particles form an active electrode layer.

4. The electrode of claim 3 , wherein the matrix further forms the current collector.

5. The electrode of claim 1 , wherein the metal foam is a nickel foam or a copper foam.

6. The electrode of claim 1 , wherein the current collector is the matrix.

7. The electrode of claim 1 , wherein the current collector comprises the matrix adjacent an active electrode layer and a solid portion opposite the active electrode layer.

8. The electrode of claim 1 , further comprising:
carbon black deposited in voids in the matrix after deposition of the first active particles and the second active particles; and
a binder.

9. A method of preparing an electrode having selectively loaded active materials, the method comprising:
preparing a first slurry of first active particles having a first particle size and a second slurry of second active particles having a second particle size;
selectively depositing the first active particles in a matrix by pulling the matrix through the first slurry, the matrix including first pores having a first size and second pores having a second size, the first size being larger than the second size, the second pores being uniformly distributed throughout the matrix, wherein the first particle size of the first active particles is smaller than the first pores and larger than the second pores;
wherein the matrix is a metal foam;
drying the matrix deposited with the first active particles;
selectively depositing the second active particles in the matrix by pulling the matrix through the second slurry; and drying the matrix deposited with the first active particles and the second active particles.

10. The method of claim 9 further comprising:
after drying the matrix deposited with the first active particles, determining a loading of the first active particles in the first pores;
when the loading is less than a predetermined first loading, repeating the selectively depositing the first active particles and drying of the matrix; and
when the loading is greater or equal to the predetermined first loading, move to selectively depositing the second active particles.

11. The method of claim 9 further comprising:
after drying the matrix deposited with the second active particles, determining a loading of the second active particles in the second pores; and
when the loading is less than a predetermined second loading, repeating the selectively depositing of the second active particles and drying of the matrix.

12. The method of claim 9 further comprising:
preparing a third slurry of carbon black and a binder;
pulling the matrix through the third slurry to deposit the carbon black and the binder into voids of the matrix where the first active particles and the second active particles are absent.

13. The method of claim 9 , wherein the first active particles are graphite and the second active particles are silicon.

14. The method of claim 9 , wherein the matrix, the first active particles and the second active particles form an active electrode layer.

15. The method of claim 9 , further comprising:
forming the matrix by:
forming a layout with first polymer beads of the first size and second polymer beads of the second size;
depositing metal on the layout; and
dissolving the first polymer beads and the second polymer beads with a solvent.

16. The method of claim 9 , wherein the metal foam is a nickel foam or a copper foam.

17. The method of claim 9 , wherein the current collector is the matrix.

18. The method of claim 9 , wherein the current collector comprises the matrix adjacent an active electrode layer and a solid portion opposite the active electrode layer.

Assignees

• Nissan North America Inc

Inventors

• Hao Xiaoguang
• Weber Jessica
• Oshihara Kenzo
• Liu Ying

Classifications

• H01M4/587

  for inserting or intercalating light metals · CPC title

• H01M4/139

  Processes of manufacture · CPC title

• H01M4/0404

  by coating on electrode collectors · CPC title

• H01M4/386

  Silicon or alloys based on silicon · CPC title

• H01M4/808

  Foamed, spongy materials · CPC title