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. A method of producing an electrode, the method comprising:
covering a metal foil with a polymer and an active material; and
pyrolyzing the covered metal foil, wherein the polymer is configured to produce a carbonized film between the active material and the metal foil.
2. The method according to claim 1 , wherein the method comprises using the electrode as an anode in a lithium-ion battery.
3. The method according to claim 1 , wherein the method comprises using the electrode as a cathode in a lithium-ion battery.
4. The method according to claim 1 , wherein the polymer comprises polyamide-imide (PAI).
5. The method according to claim 1 , wherein the pyrolysis is configured at 800° C. or less.
6. The method according to claim 1 , wherein the carbonized film is configured to prevent the formation of a metal-silicon compound.
7. The method according to claim 1 , wherein the carbonized film is configured to prevent the formation of copper silicide.
8. The method according to claim 1 , wherein the carbonized film is configured to prevent the formation of nickel silicide.
9. The method according to claim 1 , wherein the method comprises:
applying a slurry to a surface;
drying the slurry; and
peeling the dry slurry from the surface to produce the active material.
10. The method according to claim 1 , wherein the method comprises:
coating the metal foil with the polymer; and
laminating the active material to the polymer-coated metal foil.
11. The method according to claim 1 , wherein the method comprises:
coating the active material with the polymer; and
laminating the polymer-coated active material to the metal foil.
12. The method according to claim 1 , wherein the active material is configured to yield silicon constituting over 50% of weight after pyrolysis.
13. The method according to claim 1 , 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.