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

• US 9,525,168 B2
• Filed: 08/22/2014
• Issued: 12/20/2016
• 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:
  US14/466,855
• Publication Number:
  US 20150072234A1
• Time in Patent Office: 851 Days
• US Class Current: 1/1
• 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 process for manufacturing a cathode for use in a lithium ion battery, comprising:

supplying dry carbon particles and dry metal oxide particles;

supplying a dry binder consisting essentially of fibrillizable binder particles;

dry milling the dry carbon particles, dry metal oxide particles and dry binder in the absence of solvent and additional binders to form a powdered dry cathode mixture including fibrillized binder;

feeding the powdered dry cathode mixture including the fibrillized binder to a compactor to form a self-supporting dry film; and

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

2. The process of claim 1, wherein the metal oxide particles comprise lithium metal oxide particles.

3. The process of claim 2, wherein the lithium metal oxide particles comprise at least one of lithium cobalt oxide and lithium manganese oxide.

4. The process of claim 1, wherein the dry carbon particles comprise intercalated carbon particles.

5. The process of claim 1, further comprising calendering the powdered dry cathode mixture prior to applying the dry film to the electrically conductive substrate.

6. The process of claim 5, wherein the calendering comprises compressing the powdered dry cathode mixture in a roll mill.

7. The process of claim 6, wherein the roll mill is a heated roll mill.

8. The process of claim 1, wherein applying the dry film to the electrically conductive substrate comprising laminating the dry film to the electrically conductive substrate.

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

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

11. The process of claim 1, wherein the carbon particles comprise conductive carbon.

12. The process of claim 1, wherein the carbon particles comprise graphite.

13. The process of claim 1, wherein the carbon particles comprise carbon black.

14. The process of claim 1, wherein the dry binder consists essentially of a fluoropolymer.

15. The process of claim 1, wherein the powdered dry cathode mixture comprises up to 10% dry carbon particles, 50% to 96% dry metal oxide particles, and 0.5% to 30% fibrillized binder.

16. The process of claim 1, wherein the dry film has a compression density greater than or equal to 0.45 gm/cm³.

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

18. A method of manufacturing a lithium ion battery comprising:

making a cathode according to the process of claim 1;

providing an anode; and

placing the cathode and the anode into a housing with electrolyte.

19. The method of claim 18, wherein the anode comprises a milled dry mix of dry carbon and dry binder consisting essentially of fibrillated binder.

20. The method of claim 19, wherein the anode comprises a dry mix of 80% to 96% graphite, up to 10% carbon black, and 4% to 10% fibrillated binder.

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

dry milling second dry carbon particles and a second dry binder in the absence of solvent and additional binders to form a powdered dry anode mixture including fibrillized binder;

feeding the powdered dry anode mixture including the fibrillized binder to a compactor to form a second self-supporting dry film; and

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

22. The method of claim 18, wherein the anode comprises a lithium metal foil.

23. The method of claim 18, wherein the electrolyte comprises acetonitrile.

24. The method of claim 23, wherein the electrolyte comprises tetrafluoroborate in an acetonitrile solvent.

25. The method of claim 18, wherein the electrolyte comprises tetramethylammonium.

26. The method of claim 18, wherein the electrolyte comprises carbonate-based electrolytes.

27. The method of claim 26, wherein the electrolyte comprises at least one of ethylene carbonate, propylene carbonate, and dimethylcarbonate.

28. The method of claim 18, wherein the electrolyte comprises an alkaline water solution.

29. The method of claim 28, wherein the electrolyte comprises at least one of potassium hydroxide (KOH) and sodium hydroxide (NaOH).

30. The method of claim 18, wherein the electrolyte comprises an acidic water solution.

31. The method of claim 30, wherein the electrolyte comprises sulfuric acid (H₂SO₄).