Method of forming an electrode structure useful in energy storage devices

• US 20050220989A1
• Filed: 02/09/2005
• Published: 10/06/2005
• Est. Priority Date: 03/31/2004
• Status: Active Grant

• Current Assignee: Rohm and Haas Company (Dow, Inc.)
• Original Assignee: Rohm and Haas Company (Dow, Inc.)
• Inventors: Lundquist, Eric Gustave, Grieco, William Joseph, Chaturvedi, Sanjay
• Granted Patent: US 7,419,745 B2
• Time in Patent Office: Days
• US Class Current: 427/122
• CPC Class Codes: H01G 11/28 arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
• CPC Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01M 4/0419 involving spraying
• CPC Class Codes: H01M 4/0435 Rolling or calendering
• CPC Class Codes: H01M 4/0471 involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
• CPC Class Codes: H01M 4/13 Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• CPC Class Codes: H01M 4/1393 of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/583 Carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/621 Binders
• CPC Class Codes: H01M 4/622 being polymers
• CPC Class Codes: H01M 4/624 Electric conductive fillers
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/886 Powder spraying, e.g. wet or dry powder spraying, plasma spraying
• CPC Class Codes: H01M 4/8882 Heat treatment, e.g. drying, baking
• CPC Class Codes: H01M 4/8896 Pressing, rolling, calendering membrane electrode assemblies H01M8/1004
• CPC Class Codes: H01M 4/96 Carbon-based electrodes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

The present invention relates to a method for forming an electrode structure useful in energy storage devices, which method involves the spray deposition of a mixture of carbon and a binder on a current collector. In addition, the present invention relates to energy storage devices including an electrode structure produced using a spray deposition method to deposit a mixture of carbon and a binder on a current collector.

Claims

1. A method of forming an electrode structure, comprising:

(a) depositing a porous electrode on a current collector by spraying onto the current collector a mixture comprising;

(i) a carbon;

(ii) a binder; and

,

(iii) optionally, an electrically conductive additive; and

,

(b) heating the product of (a) to cure the binder.

2. The method of claim 1, wherein the mixture further comprises an electrically conductive additive.

3. The method of claim 1, wherein the porous electrode is deposited on the current collector by an electrostatic spray deposition process.

4. The method of claim 1, further comprising

(c) calendering the product of (b).

5. The method of claim 1, further comprising pretreating the current collector to modify its surface energy before depositing the porous electrode.

6. The method of claim 1, wherein the amount of binder in the mixture is in the range of 2 to 50 wt %.

7. The method of claim 1, wherein the volumetric mean particle size of the binder is less than or equal to 5 μ

m.

8. The method of claim 1, wherein the binder exhibits a volumetric mean particle size of no greater than 50% of the volumetric mean particle size exhibited by the carbon.

9. An energy storage device comprising an electrode structure prepared by the method of claim 1.

10. Use of the energy storage device of claim 9 in an automobile, power quality, engine starting, energy storage in photovoltaic, energy storage in windmills, medical system, mobile propulsion system, military electronics, transportation system, commercial electronics, consumer electronics, portable electronics, audio system or consumer appliance.