COMPOSITION AND METHOD FOR LAMINATION OF SILICON DOMINANT ANODES UTILIZING WATER BASED ADHESIVES
Disclosed are anodes created using water based adhesive solutions, low temperature methods for laminating anodes comprising water based adhesives, and alkali ion batteries that comprise the anodes.
1 . 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 adhesive material between the current collector and the film, wherein the adhesive layer comprises a mixture of polyacrylic acid (PAA) and polyvinyl alcohol (PVA) that adheres the film to the current collector.
2 . The anode of claim 1 , wherein the silicon carbon composite film is in direct contact with the current collector and the adhesive material is between the current collector and the film at the locations where the film is not in direct contact with the current collector.
3 . The anode of claim 1 , wherein at least one of PAA and PVA comprises 20-80% of the total adhesive layer.
4 . The anode of claim 3 , wherein said adhesive layer comprises 50% PAA and 50% PVA.
5 . The anode of claim 3 , wherein said adhesive layer comprises 60% PAA and 40% PVA
6 . The anode of claim 3 , wherein said adhesive layer comprises 40% PAA and 60% PVA
7 . The anode of claim 1 , wherein the adhesive layer has a final thickness of about 1 microns to about 4 microns.
8 . The anode of claim 1 , wherein the anode is a silicon dominant anode.
9 . The anode of claim 1 , wherein the current collector comprises copper.
10 . A method of forming an electrode comprising:
coating a current collector with a solution comprising a mixture of polyacrylic acid (PAA) and polyvinyl alcohol (PVA);
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.
11 . The method according to claim 10 , wherein the coating step solution comprises 20%-80% of at least one of PAA and PVA
12 . The method according to claim 10 , wherein the coating step solution comprises 40% PVA and 60% PAA.
13 . The method according to claim 10 , wherein the drying step provides a PAA/PVA layer having a final thickness of about 1 microns to about 4 microns.
14 . The method according to claim 10 , wherein the drying step comprises a temperature of about 90° C. and a time of about 1 hour.
15 . The method according to claim 10 , wherein the applying pressure and heat comprises up to about 10000 psi of pressure at temperatures less than about 200° C.
16 . The method according to claim 10 , wherein the applying pressure and heat comprises about 3000-4000 psi of pressure at about 90-200° C.
17 . The method according to claim 10 , wherein the applying pressure is between about 20 pounds/inch to about 2000 pounds/inch.
18 . The method according to claim 10 , wherein the electrode is an anode.
19 . The method according to claim 10 , wherein the electrode is a silicon carbon composite anode
20 . The method according to claim 10 , wherein the electrode is a silicon dominant anode.
21 . The method according to claim 10 , wherein the current collector comprises copper.
22 . An electrode formed by the method of claim 10 .
23 . 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 mixture of polyacrylic acid (PAA) and polyvinyl alcohol (PVA) 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.
24 . The method according to claim 23 , wherein the anode comprises a silicon dominant anode.
25 . The method according to claim 23 , wherein the current collector comprises copper.
26 . The method according to claim 23 , wherein the cathode comprises an active material comprising one or more of lithium, sodium, and potassium.
27 . The method according to claim 26 , wherein the cathode active material comprises lithium.
28 . The method according to claim 26 , wherein the cathode active material comprises lithium doped with a transition metal oxide or a non-transition metal oxide.
29 . The method according to claim 26 , wherein the cathode active material comprises 5% to 30% excess of lithium.
30 . A battery comprising:
an anode, a cathode, an electrolyte, and a separator, wherein:
the anode comprises a current collector coated with a mixture of polyacrylic acid (PAA) and polyvinyl alcohol (PVA) adhered to an anode substrate comprising a silicon carbon composite material.
31 . The battery according to claim 30 , wherein the electrolyte comprises a liquid, solid, or gel.
32 . The battery according to claim 30 , wherein the anode comprises a silicon dominant anode.
33 . The battery according to claim 30 , wherein the current collector comprises copper.
34 . The battery according to claim 30 , wherein the cathode comprises an active material comprising one or more of lithium, sodium, and potassium.
35 . The battery according to claim 34 , wherein the cathode active material comprises lithium.
36 . The battery according to claim 34 , wherein the cathode active material comprises lithium doped with a transition metal oxide or a non-transition metal oxide.
37 . The battery according to claim 34 , wherein the cathode active material comprises 5% to 30% excess of lithium.