AQUEOUS BASED POLYMERS FOR SILICON DOMINANT ANODES
Systems and methods utilizing aqueous-based polymer 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 water soluble polymer and may comprise one or more of the following materials: pH modifiers, viscosity modifiers, strengthening additives, surfactants and anti-foaming agents. The electrode coating layer may include more than 70% silicon and the anode may be in a lithium ion battery.
1 . A battery electrode, the electrode comprising:
an electrode coating layer on a current collector, the electrode coating layer comprising silicon, an aqueous-based polymer, and a secondary polymer,
wherein said aqueous-based polymer and said secondary polymer are pyrolyzed into carbon during making of the electrode; and
said aqueous-based polymer has a carbon yield upon pyrolysis of greater than about 30% and said secondary polymer has a lower carbon yield upon pyrolysis than said aqueous-based polymer.
2 . The electrode according to claim 1 , wherein said secondary polymer contributes <30% of the pyrolytic carbon.
3 . The electrode according to claim 1 , wherein said electrode coating layer further comprises one or more additional components; wherein said additional components comprise pH modifiers, viscosity modifiers, strengthening additives, surfactants and anti-foaming agents.
4 . The electrode according to claim 1 , wherein said aqueous-based polymer comprises polyimides, polyamideimides, phenolic resins, polysiloxanes, polyurethanes, polyvinyls, acrylics, polysaccharides, and derivatives thereof.
5 . The electrode according to claim 1 , wherein said aqueous-based polymer is selected from the group consisting of Polyamideimide; China-innotek; Elantas; Solvay Torlon AI series; Polyimide; Ammonium Lignosulfonate; Kraft Lignin; Phenolic resins; Formaldehyde based Resins; Melamine-formaldehyde based resins; Silane based resins; Silicones; Polyurethanes; Poly(vinyl acetate)/poly(vinyl alcohol) complexes; TOCRYL (acrylic emulsion); Poly(methacrylic acid); Polymethyl methacrylate; ACRONAL water-based acrylic and stryene-acrylic emulsion polymers; STYROFAN carboxylated styrene-butadiene; Acrylic resins; Poly(acrylic acid); Glycogen; Carbohydrates; Cellulose, Cellulose crystals (including cellulose nano-crystals); HEC (Hydroxy Ethyl Cellulose); CMHEC (Carboxy methyl hydroxy ethyl cellulose); Starch; Pullulan (polysaccharide polymer); Dextran; Chitosan; Helios resins; and Rotaxane.
6 . The electrode according to claim 1 , wherein said secondary polymer is selected from the group consisting of Polyvinylalcohol; Polyols; Polyethylene-co-vinyl alcohol; Poly(allyl alcohol); Polyesters (e.g. n-butylcellosolve); Carboxymethylcellulose; Myo-Inositol; Mannitol; Pinitol; Ribose; Sorbitol; Fucose; Maltodextrin; Ganglioside; Maltose; Sucrose; Glucose; Sucralose; Xylitol; Fructose; Palatinose hydrate; Dextran Sucrase; Guanosine; Inulin; Sucrose Phosphorylase; Glucosidases; AmberLite; Raffinose; Mannose; Psicose; Hexokinase; NADHs; Phosphoglucose; Phosphomannose; Topiramate; Furfurals; Nuciferine; Galactose; Maltose; and Hydroxymethylcellulose; Ammonium Lignosulfonate; Kraft Lignin; Formaldehyde based Resins; melamine-formaldehyde based resins; Silane based resins (gelest); silicones; polyurethanes; poly(vinyl acetate)/poly(vinyl alcohol) complexes; TOCRYL (acrylic emulsion); poly(methacrylic acid); polymethyl methacrylate; ACRONAL water-based acrylic and styrene-acrylic emulsion polymers; STYROFAN carboxylated styrene-butadiene binders; Acrylic Resins; poly (acrylic acid); glycogen; carbohydrates (other); Cellulose crystals; cellulose nano-crystals; HEC (Hydroxy Ethyl Cellulose); CMHEC (Carboxy methyl hydroxy ethyl cellulose); cellulose; Starch; Pullulan (polysaccharide polymer); Dextran; chitosan; Helios Resins (DOMOPOL (polyester); DOMACRYL (polyacrylic); DOMALKYD (polyester) and DOMEMUL (styrene/acrylic)); rotaxane; and polymeric microbeads.
7 . The electrode according to claim 3 , wherein said one or more additional component comprises one or more pH modifiers.
8 . The electrode according to claim 7 , wherein said pH modifiers are acidic pH modifiers.
9 . The electrode according to claim 7 , wherein said pH modifiers are basic pH modifiers.
10 . The electrode according to claim 3 , wherein said one or more additional component comprises one or more viscosity modifiers.
11 . The electrode according to claim 3 , wherein said one or more additional component comprises one or more strengthening additives.
12 . The electrode according to claim 3 , wherein said one or more additional component comprises one or more surfactants and/or anti-foaming agents.
13 . The electrode according to claim 3 , wherein said additional components when present comprise the amounts of:
less than about 50% pH modifier, less than about 30% strengthening additive, less than about 50% viscosity modifier, less than about 10% surfactant, less than about 10% anti-foaming agent.
14 . The electrode according to claim 1 , wherein the electrode is in electrical and physical contact with an electrolyte, the electrolyte comprising a liquid, solid, or gel.
15 . The electrode according to claim 1 , wherein the battery electrode is in a lithium ion battery.
16 . A method of forming an electrode, the method comprising:
creating an electrode coating layer from an electrode slurry comprising silicon, an aqueous-based polymer, and a secondary polymer,
fabricating a battery electrode by coating the slurry on a current collector; and
pyrolyzing said electrode coating layer into carbon; and
wherein said aqueous-based polymer has a carbon yield upon pyrolysis of greater than about 30% and said secondary polymer has a lower carbon yield upon pyrolysis than said aqueous-based polymer.
17 . The method according to claim 16 , wherein said secondary polymer contributes <30% of the pyrolytic carbon.
18 . The method according to claim 16 , wherein said electrode coating layer further comprises one or more additional components; wherein said additional components comprise pH modifiers, viscosity modifiers, strengthening additives, surfactants and anti-foaming agents.
19 . The method according to claim 16 , wherein said aqueous-based polymer comprises polyimides, polyamideimides, phenolic resins, polysiloxanes, polyurethanes, polyvinyls, acrylics, polysaccharides, and derivatives thereof.
20 . The method according to claim 16 , wherein said aqueous-based polymer is selected from the group consisting of Polyamide-imide; China-innotek; Elantas; Solvay Torlon Al series; Polyimide; Ammonium Lignosulfonate; Kraft Lignin; Phenolic resins; Formaldehyde based Resins; Melamine-formaldehyde based resins; Silane based resins; Silicones; Polyurethanes; Poly(vinyl acetate)/poly(vinyl alcohol) complexes; TOCRYL (acrylic emulsion); Poly(methacrylic acid); Polymethyl methacrylate; ACRONAL water-based acrylic and styrene-acrylic emulsion polymers; STYROFAN carboxylated styrene-butadiene; Acrylic resins; Poly(acrylic acid); Glycogen; Carbohydrates; Cellulose, Cellulose crystals (including cellulose nano-crystals); HEC (Hydroxy Ethyl Cellulose); CMHEC (Carboxy methyl hydroxy ethyl cellulose); Starch; Pullulan (polysaccharide polymer); Dextran; Chitosan; Helios resins; and Rotaxane.
21 . The method according to claim 16 , wherein said secondary polymer is selected from the group consisting of Polyvinylalcohol; Polyols; Polyethylene-co-vinyl alcohol; Poly(allyl alcohol); Polyesters (e.g. n-butylcellosolve); Carboxymethylcellulose; Myo-Inositol; Mannitol; Pinitol; Ribose; Sorbitol; Fucose; Maltodextrin; Ganglioside; Maltose; Sucrose; Glucose; Sucralose; Xylitol; Fructose; Palatinose hydrate; Dextran Sucrase; Guanosine; Inulin; Sucrose Phosphorylase; Glucosidases; AmberLite; Raffinose; Mannose; Psicose; Hexokinase; NADHs; Phosphoglucose; Phosphomannose; Topiramate; Furfurals; Nuciferine; Galactose; Maltose; and Hydroxymethylcellulose; Ammonium Lignosulfonate; Kraft Lignin; Formaldehyde based Resins; melamine-formaldehyde based resins; Silane based resins (gelest); silicones; polyurethanes; poly(vinyl acetate)/poly(vinyl alcohol) complexes; TOCRYL (acrylic emulsion); poly(methacrylic acid); polymethyl methacrylate; ACRONAL water-based acrylic and styrene-acrylic emulsion polymers; STYROFAN carboxylated styrene-butadiene binders; Acrylic Resins; poly (acrylic acid); glycogen; carbohydrates (other); Cellulose crystals; cellulose nano-crystals; HEC (Hydroxy Ethyl Cellulose); CMHEC (Carboxy methyl hydroxy ethyl cellulose); cellulose; Starch; Pullulan (polysaccharide polymer); Dextran; chitosan; Helios Resins (DOMOPOL (polyester); DOMACRYL (polyacrylic); DOMALKYD (polyester) and DOMEMUL (styrene/acrylic)); rotaxane; and polymeric microbeads.
22 . The method according to claim 18 , wherein said one or more additional component comprises one or more pH modifiers.
23 . The method according to claim 22 , wherein said pH modifiers are acidic pH modifiers.
24 . The method according to claim 22 , wherein said pH modifiers are basic pH modifiers.
25 . The method according to claim 18 , wherein said one or more additional component comprises one or more viscosity modifiers.
26 . The method according to claim 18 , wherein said one or more additional component comprises one or more strengthening additives.
27 . The electrode according to claim 18 , wherein said one or more additional component comprises one or more surfactants and/or anti-foaming agents.
28 . The method according to claim 18 , wherein said additional components when present comprise the amounts of:
less than about 50% pH modifier, less than about 30% strengthening additive, less than about 50% viscosity modifier, less than about 10% surfactant, less than about 10% anti-foaming agent.
29 . 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.
30 . The method according to claim 16 , wherein the battery electrode is in a lithium ion battery.