Method and system for water based phenolic binders for silicon-dominant anodes
Systems and methods for water based phenolic binders for silicon-dominant anodes may include an electrode coating layer on a current collector, where the electrode coating layer is formed from silicon and a pyrolyzed water-based phenolic binder. The water-based phenolic binder may include phenolic/resol type polymers crosslinked with poly(methyl vinyl ether-alt-maleic anhydride), poly(methyl vinyl ether-alt-maleic acid), and/or Poly(acrylamide-co-diallyldimethylammonium chloride) (PDADAM). The electrode coating layer may further include conductive additives. The current collector may comprise one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer. The electrode coating layer may include more than 70% silicon. The electrode may be in electrical and physical contact with an electrolyte, where the electrolyte includes a liquid, solid, or gel. The battery electrode may be in a lithium ion battery.
1. A method of forming an electrode, the method comprising:
creating an electrode coating layer from an electrode slurry comprising an aqueous solution of a water-based phenolic binder and Si powder, with optional additives;
fabricating a battery electrode by coating the slurry on a current collector; and
pyrolyzing said electrode coating layer;
wherein the water-based phenolic binder comprises a phenolic/resol type polymer crosslinked with poly(methyl vinyl ether-alt-maleic anhydride).
2. The method according to claim 1 , wherein the electrode coating layer further comprises conductive additives.
3. The method according to claim 1 , wherein the current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer.
4. The method according to claim 1 , wherein the electrode coating layer comprises more than 70% silicon.
5. The method according to claim 1 , wherein the electrode is in electrical and physical contact with an electrolyte, the electrolyte comprising a liquid, solid, or gel.
6. A method of forming an electrode, the method comprising:
creating an electrode coating layer from an electrode slurry comprising an aqueous solution of a water-based phenolic binder and Si powder, with optional additives;
fabricating a battery electrode by coating the slurry on a current collector; and
pyrolyzing said electrode coating layer;
wherein the water-based phenolic binder comprises a phenolic/resol type polymer crosslinked with poly(methyl vinyl ether-alt-maleic acid).
7. The method according to claim 6 , wherein the electrode coating layer further comprises conductive additives.
8. The method according to claim 6 , wherein the current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer.
9. The method according to claim 6 , wherein the electrode coating layer comprises more than 70% silicon.
10. The method according to claim 6 , wherein the electrode is in electrical and physical contact with an electrolyte, the electrolyte comprising a liquid, solid, or gel.
11. A method of forming an electrode, the method comprising:
creating an electrode coating layer from an electrode slurry comprising an aqueous solution of a water-based phenolic binder and Si powder, with optional additives;
fabricating a battery electrode by coating the slurry on a current collector; and
pyrolyzing said electrode coating layer;
wherein the water-based phenolic binder comprises a phenolic/resol type polymer crosslinked with poly(acrylamide-co-diallyldimethylammonium chloride) (PDADAM).
12. The method according to claim 11 , wherein the electrode coating layer further comprises conductive additives.
13. The method according to claim 11 , wherein the current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer.
14. The method according to claim 11 , wherein the electrode coating layer comprises more than 70% silicon.
15. The method according to claim 11 , wherein the electrode is in electrical and physical contact with an electrolyte, the electrolyte comprising a liquid, solid, or gel.
16. A method of forming an electrode, the method comprising:
creating an electrode coating layer from an electrode slurry comprising an aqueous solution of a water-based phenolic binder and Si powder, with optional additives;
fabricating a battery electrode by coating the slurry on a current collector; and
pyrolyzing said electrode coating layer;
wherein the water-based phenolic binder comprises a phenol-crotonaldehyde-resorcinol derivative.
17. The method according to claim 16 , wherein the electrode coating layer further comprises conductive additives.
18. The method according to claim 16 , wherein the current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer.
19. The method according to claim 16 , wherein the electrode coating layer comprises more than 70% silicon.
20. The method according to claim 16 , wherein the electrode is in electrical and physical contact with an electrolyte, the electrolyte comprising a liquid, solid, or gel.
21. A method of forming an electrode, the method comprising:
creating an electrode coating layer from an electrode slurry comprising an aqueous solution of a water-based phenolic binder and Si powder, with optional additives;
fabricating a battery electrode by coating the slurry on a current collector; and
pyrolyzing said electrode coating layer;
wherein the water-based phenolic binder comprises a phenolic/resol type polymer derivatized by one or more functional groups selected from the group consisting of ethers, polyethoxylates, esters, glycolipids, phosphates, oxiranes, and/or carbamates.
22. The method according to claim 21 , wherein the electrode coating layer further comprises conductive additives.
23. The method according to claim 21 , wherein the current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer.
24. The method according to claim 21 , wherein the electrode coating layer comprises more than 70% silicon.
25. The method according to claim 21 , wherein the electrode is in electrical and physical contact with an electrolyte, the electrolyte comprising a liquid, solid, or gel.