REACTION BARRIER BETWEEN ELECTRODE ACTIVE MATERIAL AND CURRENT COLLECTOR
Systems and methods are provided for a reaction barrier between an electrode active material and a current collector. An electrode may comprise an active material, a metal foil, and a polymer. The polymer (such as polyamide-imide (PAI)) may be configured to provide a carbonized barrier between the active material and the metal foil after pyrolysis.
1 . An electrode, the electrode comprising:
an active material;
a metal foil; and
a carbonized film between the active material and the metal foil, wherein the carbonized film comprises a composition resulting from a pyrolysis of a polymer in a varnish.
2 . The electrode according to claim 1 , wherein a lithium-ion battery comprises the electrode as an anode.
3 . The electrode according to claim 1 , wherein a lithium-ion battery comprises the electrode as a cathode.
4 . The electrode according to claim 1 , wherein the polymer comprises polyamide-imide (PAI).
5 . The electrode according to claim 1 , wherein the pyrolysis configured at 800° C. or less.
6 . The electrode according to claim 1 , wherein the carbonized film is configured to prevent the formation of a metal-silicon compound.
7 . The electrode according to claim 1 , wherein the carbonized film is configured to prevent the formation of copper silicide.
8 . The electrode according to claim 1 , wherein the carbonized film is configured to prevent the formation of nickel silicide.
9 . The electrode according to claim 1 , wherein the polymer is added to the active material prior to a coating of the metal foil.
10 . The electrode according to claim 1 , wherein the metal foil is coated by the polymer.
11 . The electrode according to claim 1 , wherein the active material is configured to yield silicon constituting over 50% of weight of the electrode after pyrolysis.
12 . The electrode according to claim 1 , wherein the polymer is applied on the metal foil prior to a direct placement of slurry comprising the active material.
13 . A method of producing an electrode, the method comprising:
covering a metal foil with a polymer, wherein the polymer is applied to the metal foil as a varnish; and
pyrolyzing the covered metal foil, wherein the polymer is configured to produce a carbonized film.
14 . The method according to claim 13 , wherein the method comprises using the electrode as an anode in a lithium-ion battery.
15 . The method according to claim 13 , wherein the method comprises using the electrode as a cathode in a lithium-ion battery.
16 . The method according to claim 13 , wherein the polymer comprises polyamide-imide (PAI).
17 . The method according to claim 13 , wherein the pyrolysis is configured at 800° C. or less.
18 . The method according to claim 13 , wherein the carbonized film is configured to prevent the formation of a metal-silicon compound.
19 . The method according to claim 13 , wherein the carbonized film is configured to prevent the formation of copper silicide.
20 . The method according to claim 13 , wherein the carbonized film is configured to prevent the formation of nickel silicide.
21 . The method according to claim 13 , wherein the method comprises applying a slurry to a surface of the metal foil, wherein the surface of the metal foil comprises the carbonized film.
22 . The method according to claim 13 , wherein the method comprises mixing a slurry with a binder prior to coating the metal foil with the slurry, and wherein the binder and the polymer comprise identical material.
23 . The method according to claim 13 , wherein the method comprises laminating a polymer-coated active material to the metal foil.
24 . The method according to claim 13 , wherein the active material is configured to yield silicon constituting over 50% of weight after pyrolysis.
25 . The method according to claim 13 , wherein the method comprises:
coating the metal foil with the polymer;
coating the polymer-coated metal foil with the active material; and
pyrolyzing the active-material-coated, polymer-coated metal foil.