Electrodepositable battery electrode coating compositions having coated active particles

1. An electrodepositable coating composition comprising:

an electrochemically active particle at least partially coated with a protective coating, wherein the electrochemically active particle comprises a material for use as an active material for a positive electrode or a material for use as an active material for a negative electrode;

an electrodepositable binder; and

an aqueous medium.

2. The electrodepositable coating composition of claim 1 , wherein the protective coating comprises a metal compound or complex.

3. The electrodepositable coating composition of claim 2 , wherein the metal compound or complex comprises (i) a metal chalcogen; (ii) a metal pnictogen; (iii) a metal halide; (iv) a metal oxyhalide; (v) a metal oxynitride; (vi) a metal phosphate; (vi) a metal carbide; (vii) a metal oxycarbide; (viii) a metal carbonitride; (ix) an olivine; (x) a NaSICON structure; (xi) a polymetallic ionic structure; (xii) a metal organic structure or complex; (xiii) a polymetallic organic structure or complex; or (xiv) a metal carbon-based coating.

4. The electrodepositable coating composition of claim 1 , wherein the protective coating comprises a metal-oxide coating.

5. The electrodepositable coating composition of claim 4 , wherein the metal-oxide of the metal-oxide coating comprises an oxide of titanium.

6. The electrodepositable coating composition of claim 5 , wherein the oxide of titanium comprises titania.

7. The electrodepositable coating composition of claim 4 , wherein the metal-oxide of the metal-oxide coating comprises an oxide of aluminum.

8. The electrodepositable coating composition of claim 7 , wherein the oxide of aluminum comprises alumina.

9. The electrodepositable coating composition of claim 1 , wherein the protective coating comprises a carbon-based coating.

10. The electrodepositable coating composition of claim 9 , wherein the carbon-based coating comprises a metal carbonate.

11. The electrodepositable coating composition of claim 10 , wherein the carbon-based coating comprises lithium carbonate.

12. The electrodepositable coating composition of claim 1 , wherein the protective coating comprises a non-metal compound or complex.

13. The electrodepositable coating composition of claim 12 , wherein the non-metal compound or complex comprises (i) a non-metal oxide; (ii) a non-metal nitride; (iii) a non-metal carbonitride; (iv) a non-metal fluoride; (v) a non-metallic organic structures or complexes; (vi) or a non-metal oxyfluoride.

14. The electrodepositable coating composition of claim 1 , wherein the electrochemically active particle comprises a material capable of incorporating lithium, and the material capable of incorporating lithium comprises LiCoO 2 , LiNiO 2 , LiFePO 4 , LiCoPO 4 , LiMnO 2 , LiMn 2 O 4 , Li(NiMnCo)O 2 , Li(NiCoAl)O 2 , carbon-coated LiFePO 4 , or a combination thereof.

15. The electrodepositable coating composition of claim 1 , wherein the electrochemically active particle comprises a material capable of lithium conversion, and the material capable of lithium conversion comprises sulfur, LiO 2 , FeF 2 and FeF 3 , Si, aluminum, tin, SnCo, Fe 3 O 4 , or combinations thereof.

16. The electrodepositable coating composition of claim 1 , wherein the electrodepositable binder comprises a fluoropolymer.

17. The electrodepositable coating composition of claim 1 , wherein the electrodepositable binder comprises a pH-dependent rheology modifier.

18. The electrodepositable coating composition of claim 17 , wherein the pH-dependent rheology modifier comprises an alkali-swellable rheology modifier.

19. The electrodepositable coating composition of claim 17 , wherein the pH-dependent rheology modifier comprises an acid-swellable rheology modifier.

20. The electrodepositable coating composition of claim 16 , wherein the electrodepositable binder further comprises a dispersant.

21. The electrodepositable coating composition of claim 1 , wherein the electrodepositable binder comprises an ionic, film-forming resin.

22. The electrodepositable coating composition of claim 15 , further comprising a curing agent.

23. A method of coating a substrate, the method comprising:

electrophoretically depositing the electrodepositable coating composition of claim 1 onto a substrate.

24. A coated substrate comprising an electrical current collector and a coating formed on the at least a portion of the electrical current collector, wherein the coating is deposited from the electrodepositable coating composition of claim 1 .

25. The coated substrate of claim 24 , wherein the electrical current collector comprises aluminum, copper, steel, stainless steel, nickel, conductive carbon, a conductive primer coating, or an electrically conductive porous polymer.

26. The coated substrate of claim 24 , wherein the coated substrate comprises a positive electrode.

27. The coated substrate of claim 24 , wherein the coated substrate comprises a negative electrode.

28. The coated substrate of claim 24 , wherein the electrical current collector is pretreated with a pretreatment composition.

29. An electrical storage device comprising:

(a) an electrode comprising the coated substrate of claim 24 ;

(b) a counter-electrode, and

(c) an electrolyte.

30. The electrical storage device of claim 29 , wherein the electrical storage device comprises a cell.

31. The electrical storage device of claim 29 , wherein the electrical storage device comprises a battery pack.

32. The electrical storage device of claim 29 , wherein the electrical storage device comprises a secondary battery.

33. The electrical storage device of claim 29 , wherein the electrical storage device comprises a capacitor.

34. The electrical storage device of claim 29 , wherein the electrical storage device comprises a supercapacitor.

35. The electrical storage device of claim 29 , wherein the electrical storage device comprises a pseudocapacitor.