Dry-particle based adhesive and dry film and methods of making same

• US 8,815,443 B2
• Filed: 03/10/2010
• Issued: 08/26/2014
• Est. Priority Date: 07/09/2003
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Maxwell Technologies Incorporated (Tesla Inc.)
• Inventors: Mitchell, Porter, Xi, Xiaomei, Zhong, Linda, Zou, Bin
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): Lewis, Ben
• Application Number:
  US12/720,910
• Publication Number:
  US 20100263910A1
• Time in Patent Office: 1,630 Days
• Field of Search: 429/405, 429/481, 429/484, 429/509, 429/523, 429/209, 429/212, 429/213, 429/217, 429/231.95
• US Class Current: 429/209
• 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 11/38 Carbon pastes or blends; Binders or additives therein
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 4/02 Electrodes composed of, or comprising, active material
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0409 by a doctor blade method, slip-casting or roller coating
• CPC Class Codes: H01M 4/0416 involving impregnation with a solution, dispersion, paste or dry powder H01M4/0438 takes precedence
• CPC Class Codes: H01M 4/0435 Rolling or calendering
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1391 of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1393 of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 4/505 of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
• CPC Class Codes: H01M 4/525 of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• CPC Class Codes: H01M 4/58 of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
• CPC Class Codes: H01M 4/583 Carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 4/62 Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
• CPC Class Codes: H01M 4/621 : Binders
• CPC Class Codes: H01M 4/622 : being polymers
• CPC Class Codes: H01M 4/623 : fluorinated polymers
• CPC Class Codes: H01M 4/625 : Carbon or graphite
• CPC Class Codes: H01M 4/8668 : Binders
• CPC Class Codes: H01M 4/8673 : Electrically conductive fillers
• CPC Class Codes: H01M 4/886 : Powder spraying, e.g. wet or dry powder spraying, plasma spraying
• CPC Class Codes: H01M 4/8896 : Pressing, rolling, calendering membrane electrode assemblies H01M8/1004
• CPC Class Codes: H01M 4/9041 : Metals or alloys H01M4/92 takes precedence
• CPC Class Codes: H01M 4/9083 : on carbon or graphite
• CPC Class Codes: H01M 4/926 : on carbon or graphite
• 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
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 428/28 : Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/2878 : including addition polymer from unsaturated monomer
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31678 : Of metal

Abstract

Dry process based energy storage device structures and methods for using a dry adhesive therein are disclosed.

Claims

1. A method of manufacturing a lithium ion battery, the method comprising:

dry milling dry carbon particles, dry lithium compound particles, and dry binder consisting essentially of fibrillizable binder particles, wherein the dry milling is performed in the absence of solvent and additional binders to form a milled dry cathode powdered mixture;

feeding the milled dry cathode powdered mixture to rollers;

calendering the milled dry cathode powdered mixture between the rollers to form a dry cathode film;

applying the dry cathode film to an electrically conductive substrate to form the cathode;

providing an anode; and

placing the cathode and the anode in a housing comprising an electrolyte to form the lithium ion battery.

2. The method of claim 1, wherein the dry carbon particles comprise conductive carbon particles.

3. The method of claim 1, wherein the dry carbon particles comprise graphite particles.

4. The method of claim 1, wherein the dry carbon particles comprise carbon black particles.

5. The method of claim 1, wherein the lithium compound particles comprise lithium metal oxide particles.

6. The method of claim 5, wherein the lithium metal oxide particles comprise at least one of lithium cobalt oxide particles and lithium manganese oxide particles.

7. The method of claim 1, wherein the dry binder consists essentially of fluoropolymer particles.

8. The method of claim 1, wherein the dry binder consists essentially of polytetrafluoroethylene (PTFE).

9. The method of claim 1, wherein the dry binder consists of polytetrafluoroethylene (PTFE).

10. The method of claim 1, wherein the dry milling comprises jet milling.

11. The method of claim 1, wherein the dry milling comprises dry milling up to 10% dry carbon particles, 50% to 96% dry lithium compound particles, and 0.5% to 30% fibrillizable binder particles to form the dry cathode film.

12. The method of claim 1, wherein calendering the milled dry cathode powdered mixture comprises compressing the milled dry cathode powdered mixture in a roll mill.

13. The method of claim 12, wherein the roll mill is a heated roll mill.

14. The method of claim 1, wherein the dry cathode film is a self-supporting dry cathode film.

15. The method of claim 1, wherein the dry cathode film has a compression density greater than or equal to about 0.45 gm/cm³.

16. The method of claim 1, wherein applying the dry cathode film to the electrically conductive substrate comprising laminating the dry cathode film to the electrically conductive substrate.

17. The method of claim 1, wherein the electrically conductive substrate comprises a metal foil.

18. The method of claim 1, wherein providing the anode comprises:

dry milling second dry carbon particles and a second dry binder consisting essentially of fibrillizable binder particles, wherein the dry milling is performed in the absence of solvent and additional binders to form a milled dry anode powdered mixture;

compressing the dry anode powdered mixture to form a dry anode film; and

applying the dry anode film to a second electrically conductive substrate to form the anode.

19. The method of claim 18, wherein the dry milling to form a dry anode mixture comprises dry mixing 80% to 96% graphite, up to 10% carbon black, and 4% to 10% fibrillizable binder particles to form a dry anode film.

20. The method of claim 1, wherein the dry milling comprises pin milling.

21. The method of claim 1, wherein the dry milling comprises roll milling.

22. The method of claim 1, wherein the dry milling comprises hammer milling.

23. The method of claim 1, wherein the dry mixture is a dry particulate mixture.

24. The method of claim 23, wherein the dry particulate mixture is a dry powdered mixture.