Nanocomposite electrodes and related devices
First Claim
1. A nanocomposite electrode, comprising:
- a current collector;
an electroactive layer comprising an electroactive material having a surface area of at least about 10 m2/g and a first polymer;
wherein the first polymer is selected from a group consisting of a polyvinylidene fluoride polymer, a copolymer thereof, and a terpolymer thereof; and
a conductive adhesive layer contacting the surface of the current collector, wherein the conductive adhesive layer comprises a second polymer selected from the group consisting of a polyolefin, a polyurethane, a polyacrylic acid, a polyacrylic ester, a polyether, a polyacrylate, a polystyrene, a copolymer thereof, a terpolymer thereof, and a mixture thereof; and
an interlayer region interposed between the conductive adhesive layer and the electroactive layer and in electrical communication with the current collector and the electroactive layer, the interlayer region comprising a portion of the conductive adhesive layer intermixed with a portion of the electroactive material.
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Accused Products
Abstract
A nanocomposite electrode that includes a current collector, an electroactive layer a conductive adhesive contacting the surface of the current collector and an interlayer region in electrical communication with the current collector and the electroactive material. The interlayer region is interposed between the current collector and the electroactive layer and includes a portion of the conductive adhesive intermixed with a portion of the electroactive layer. The electroactive layer includes electroactive material having a surface area of at least about 10 m2/g. The conductive adhesive may be at least partially soluble in electrode casting solvent. Electrochemical devices, such as lithium secondary cells, containing an electrode with an interlayer region are also provided, as are processes for making such electrodes and electrochemical devices.
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Citations
91 Claims
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1. A nanocomposite electrode, comprising:
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a current collector; an electroactive layer comprising an electroactive material having a surface area of at least about 10 m2/g and a first polymer;
wherein the first polymer is selected from a group consisting of a polyvinylidene fluoride polymer, a copolymer thereof, and a terpolymer thereof; anda conductive adhesive layer contacting the surface of the current collector, wherein the conductive adhesive layer comprises a second polymer selected from the group consisting of a polyolefin, a polyurethane, a polyacrylic acid, a polyacrylic ester, a polyether, a polyacrylate, a polystyrene, a copolymer thereof, a terpolymer thereof, and a mixture thereof; and an interlayer region interposed between the conductive adhesive layer and the electroactive layer and in electrical communication with the current collector and the electroactive layer, the interlayer region comprising a portion of the conductive adhesive layer intermixed with a portion of the electroactive material. - View Dependent Claims (2, 3, 4, 5, 6, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 89)
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7. (canceled)
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24-44. -44. (canceled)
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45. A lithium secondary cell, comprising:
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a lithium-containing positive electrode in electronic contact with a positive electrode current collector, the positive electrode current collector in electrical connection with an external circuit; a negative electrode in electronic contact with a negative electrode current collector, the negative electrode current collector in electrical connection with an external circuit; and an electrolyte in ionic contact with the positive and negative electrodes, wherein the positive electrode comprises an electroactive layer comprising an electroactive material having a surface area of at least about 10 m2/g and a first polymer;
wherein the first polymer is selected from a group consisting of a polyvinylidene fluoride polymer, a copolymer thereof, and a terpolymer thereof;a conductive adhesive layer contacting the surface of the positive current collector, wherein the conductive adhesive layer comprises a second polymer selected from the group consisting of a polyolefin, a polyurethane, a polyacrylic acid, a polyacrylic ester, a polyether, a polyacrylate, a polystyrene, a copolymer thereof, a terpolymer thereof, and a mixture thereof; and an interlayer region interposed between the conductive adhesive layer and the electroactive layer and in electrical communication with the positive current collector and the electroactive layer, the interlayer region comprising a portion of the conductive adhesive intermixed with a portion of the electroactive material. - View Dependent Claims (46, 47, 48, 49, 50, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 91)
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51. (canceled)
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67. A process for preparing a lithium-containing electrode, comprising:
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applying a conductive adhesive layer to one or more surfaces of a current collector, forming a current collector coated with an adhesive layer, wherein the conductive adhesive layer comprises a second polymer selected from the group consisting of a polyolefin, a polyurethane, a polyacrylic acid, a polyacrylic ester, a polyether, a polyacrylate, a polystyrene, a copolymer thereof, a terpolymer thereof, and a mixture thereof; applying an electroactive layer composition to one or more surfaces of the coated current collector, the electroactive layer composition comprising electroactive material, a first polymer and electrode casting solvent, wherein the electroactive material has a surface area of at least about 10 m2/g and ther first polymer is selected from a group consisting of a polyvinylidene fluoride polymer, a copolymer thereof, and a terpolymer thereof;
whereina portion of the high surface area electroactive material intermixes with the adhesive to form an interlayer region interposed between the conductive adhesive layer and the electroactive layer and in electrical communication with the coated current collector and the remainder of the high surface area electroactive material, the interlayer region comprising a portion of the conductive adhesive layer intermixed with a portion of the electroactive material. - View Dependent Claims (68, 69, 70, 71, 72, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88)
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73. (canceled)
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90. (canceled)
Specification