Composition and method for lamination of silicon dominant electrodes

1. A method for preparing a maleic anhydride-grafted cyclic olefin copolymer comprising:

mixing a solution comprising a cyclic olefin copolymer with a solution of maleic anhydride to form a reaction mixture;

adding a radical initiator to the reaction mixture; and

maintaining the reaction mixture under conditions that allow for the formation of the maleic anhydride-grafted olefin copolymer.

2. The method according to claim 1 , wherein the cyclic olefin copolymer has a structure according to Formula I:

wherein A is a C 5 -C 12 carbocyclic ring, optionally substituted with one or more C 1-6 alkyl, C 2-6 alkenyl, or aryl groups; and

x and y are integers, wherein the ratio of x:y falls within a range of about 6:1 to about 1.5:1.

3. The method according to claim 2 , wherein A is selected from the group consisting of cyclopentyl, tetracyclododecenes, tetracyclododecenes, norbornanes (bicyclo[2.2.1]heptanes), and norbornenes (bicyclo[2.2.1]hept-2-enes).

4. The method according to claim 1 , wherein the radical initiator is selected from the group consisting of azo compounds and peroxides.

5. The method according to claim 4 , wherein the radical initiator is azobisisobutyronitrile (AIBN).

6. The method according to claim 1 , wherein the reaction mixture comprises a cyclohexane/toluene solvent system.

7. The method according to claim 1 , wherein the conditions that allow for the formation of the maleic anhydride-grafted olefin copolymer comprise heating the reaction mixture to a temperature range of 40° C. to 100° C.

8. The method according to claim 1 , wherein the conditions that allow for the formation of the maleic anhydride-grafted olefin copolymer comprise heating the reaction mixture to a temperature range of 50° C. to 60° C.

9. The method according to claim 1 , wherein the conditions that allow for the formation of the maleic anhydride-grafted olefin copolymer comprise heating the reaction mixture to a temperature range of about 55° C.

10. The method according to claim 1 , wherein the conditions that allow for the formation of the maleic anhydride-grafted olefin copolymer are maintained for about 8 hours to about 20 hours.

11. The method according to claim 1 , wherein the conditions that allow for the formation of the maleic anhydride-grafted olefin copolymer are maintained for about 16 hours.

12. The method according to claim 1 , wherein the conditions that allow for the formation of the maleic anhydride-grafted olefin copolymer comprise heating the reaction mixture to a temperature range of 50° C. to 60° C. for about 16 hours.

13. A maleic anhydride-grafted cyclic olefin copolymer.

14. A maleic anhydride-grafted cyclic olefin copolymer prepared by the method of claim 1 .

15. A method of forming an electrode comprising:

coating a current collector with a solution comprising a maleic anhydride-grafted cyclic olefin copolymer;

drying the coated current collector; and

applying pressure and heat to the coated current collector and a solid film comprising electrochemically active material under conditions to adhere the coated current collector to the solid film to form the electrode.

16. The method according to claim 15 , wherein the electrode is an anode.

17. The method according to claim 15 , wherein the electrode is a silicon carbon composite anode.

18. The method according to claim 15 , wherein the electrode is a silicon dominant anode.

19. The method according to claim 15 , wherein the current collector comprises copper.

20. The method according to claim 15 , wherein the coating step comprises a 7.5% solution of maleic anhydride-grafted cyclic olefin copolymer.

21. The method according to claim 15 , wherein the polymer coating layer has a final thickness of about 2 microns to about 5 microns.

22. The method according to claim 15 , wherein the polymer coating layer has a final thickness of about 3 microns.

23. The method according to claim 15 , wherein the drying step comprises a temperature of about 110° C. and a time of about 16 hours.

24. The method according to claim 15 , wherein the drying step comprises a temperature of about 110° C. and a time of about 16 hours.

25. The method according to claim 15 , wherein the applying pressure and heat comprises about 4000 psi of pressure at about 150° C. for a time of about 50 seconds.

26. An electrode formed by the method of claim 15 .

27. An anode comprising: a current collector; a solid film comprising electrochemically active material in electrical communication with the current collector, the film comprising a silicon carbon composite film; and a layer of material between the current collector and the film, wherein the layer comprises a maleic anhydride-grafted cyclic olefin copolymer that adheres the film to the current collector.

28. The anode of claim 27 wherein the anode is a silicon dominant anode.

29. The method according to claim 27 , wherein the current collector comprises copper.

30. A method of forming a battery, the method comprising:

providing an anode, a cathode, and a separator, the anode comprising a current collector coated with a maleic anhydride-grafted cyclic olefin copolymer adhered to an anode substrate comprising a silicon carbon composite material; and

assembling the cathode, the separator, and the anode, with an electrolyte to form the battery.

31. The method according to claim 30 , wherein the anode comprises a silicon dominant anode.

32. The method according to claim 30 , wherein the current collector comprises copper.

33. The method according to claim 30 , wherein the cathode comprises an active material comprising one or more of lithium, sodium, and potassium.

34. The method according to claim 33 , wherein the cathode active material comprises lithium.

35. The method according to claim 33 , wherein the cathode active material comprises lithium doped with a transition metal oxide or a non-transition metal oxide.

36. The method according to claim 33 , wherein the cathode active material comprises 5% to 30% excess of lithium.

37. A battery comprising:

an anode, a cathode, an electrolyte, and a separator, wherein:

the anode comprises a current collector coated with a maleic anhydride-grafted cyclic olefin copolymer adhered to an anode substrate comprising a silicon carbon composite material.

38. The battery according to claim 37 , wherein the electrolyte comprises a liquid, solid, or gel.

39. The battery according to claim 37 , wherein the anode comprises a silicon dominant anode.

40. The battery according to claim 37 , wherein the current collector comprises copper.

41. The battery according to claim 37 , wherein the cathode comprises an active material comprising one or more of lithium, sodium, and potassium.

42. The battery according to claim 41 , wherein the cathode active material comprises lithium.

43. The battery according to claim 41 , wherein the cathode active material comprises lithium doped with a transition metal oxide or a non-transition metal oxide.

44. The battery according to claim 41 , wherein the cathode active material comprises 5% to 30% excess of lithium.