Electrode slurry composition for lithium ion electrical storage devices

1. A slurry composition comprising:

(a) a binder comprising a polymer comprising a fluoropolymer dispersed in an aqueous medium; and

(b) at least one conductive carbon material having a BET surface area of greater than 100 m 2 /g.

2. The slurry composition of claim 1 , wherein the conductive carbon material has a BET surface area of 100.1 m 2 /g to 1,000 m 2 /g.

3. The slurry composition of claim 1 , wherein the conductive carbon has a BET surface area of 200 m 2 /g.

4. The slurry composition of claim 1 , wherein the conductive carbon comprises carbon nanotubes.

5. The slurry composition of claim 1 , further comprising an electrochemically active material.

6. The slurry composition of claim 5 , wherein

(a) the binder is present in amounts of 1 to 20 percent by weight;

(b) the conductive carbon material is present in amounts of 2 to 20 percent by weight; and

(c) the electrochemically active material is present in amounts of 45 to 96 percent by weight; the percentages by weight based on total solids weight.

7. The slurry composition of claim 5 , wherein the electrochemically active material comprises a material capable of incorporating lithium.

8. The slurry composition of claim 7 , wherein material capable of incorporating lithium comprises LiCoO 2 , LiNiO 2 , LiFePO 4 , LiCoPO 4 , LiMnO 2 , LiMn 2 O 4 , Li(NiMnCo)O 2 , Li(NiCoAl)O 2 , carbon-coated LiFePO 4 , or a combination thereof.

9. The slurry composition of claim 5 , wherein the electrochemically active material comprises a material capable of lithium conversion.

10. The slurry composition of claim 9 , wherein the material capable of lithium conversion comprises sulfur, LiO 2 , FeF 2 and FeF 3 , Si, aluminum, tin, SnCo, Fe 3 O 4 , or combinations thereof.

11. The slurry composition of claim 5 , wherein the electrochemically active material comprises graphite, silicon compounds, tin, tin compounds, sulfur, sulfur compounds, or a combination thereof.

12. The slurry composition of claim 5 , wherein the slurry has a total solids content of 55 percent by weight or greater and a viscosity of no more than 4,000 cPa as measured by an Anton-Paar rheometer having a model number MCR301 using a 50-millimeter cone and temperature-controlled plate at 25° C.

13. The slurry composition of claim 1 , wherein the fluoropolymer comprises a (co)polymer comprising the residue of vinylidene fluoride.

14. The slurry composition of claim 1 , wherein the fluoropolymer comprises a polyvinylidene fluoride polymer.

15. The slurry composition of claim 1 , further comprising an adhesion promoter.

16. The slurry composition of claim 15 , wherein the adhesion promoter comprising a polyvinylidene fluoride copolymer, an acid-functional polyolefin, or a thermoplastic material.

17. The slurry composition of claim 16 , wherein the polyvinylidene fluoride copolymer comprises constitutional units comprising the residue of vinylidene fluoride and at least one of:

(i) a (meth)acrylic acid; and/or

(ii) a hydroxyalkyl (meth)acrylate.

18. The slurry composition of claim 16 , wherein the acid-functional polyolefin comprises an ethylene-acrylic acid copolymer.

19. The slurry composition of claim 1 , further comprising a dispersant.

20. The slurry composition of claim 19 , wherein the dispersant comprises an addition polymer.

21. The slurry composition of claim 20 , wherein the addition polymer comprises an active hydrogen group.

22. The slurry composition of claim 21 , wherein the active hydrogen group comprises at least one carboxylic acid group, at least one hydroxyl group, or combinations thereof.

23. The slurry composition of claim 20 , wherein the addition polymer comprises a (meth)acrylic polymer comprising constitutional units comprising the residue of methyl methacrylate.

24. The slurry composition of claim 23 , wherein the (meth)acrylic polymer further comprises constitutional units comprising the residue of ethylenically unsaturated monomer comprising a heterocyclic group.

25. The slurry composition of claim 24 , wherein the (meth)acrylic polymer comprises at least one epoxy functional group, and the epoxy functional group is post-reacted with a beta-hydroxy functional acid.

26. The slurry composition of claim 19 , wherein the composition further comprises a cross-linker.

27. The slurry composition of claim 1 , wherein the slurry is substantially free of isophorone.

28. The slurry composition of claim 1 , wherein the slurry is substantially free of N-methyl-2-pyrrolidone.

29. An electrode comprising:

(a) an electrical current collector; and

(b) a film formed on the electrical current collector, wherein the film is deposited from the slurry composition of claim 5 .

30. The electrode of claim 29 , wherein the electrical current collector (a) comprises copper or aluminum in the form of a mesh, sheet or foil.

31. The electrode of claim 29 , wherein the electrode comprises a positive electrode.

32. The electrode of claim 29 , wherein the electrode comprises a negative electrode.

33. The electrode of claim 29 , wherein the film is cross-linked.

34. The electrode of claim 29 , wherein the electrical current collector is pretreated with a pretreatment composition.

35. The electrode of claim 29 , wherein the film has a thickness of at least 1 micron.

36. The electrode of claim 29 , wherein the film has a uniform composition.

37. An electrical storage device comprising:

(a) the electrode of claim 29 ;

(b) a counter electrode; and

(c) an electrolyte.

38. The electrical storage device of claim 37 , wherein the electrolyte (c) comprises a lithium salt dissolved in a solvent.

39. The electrical storage device of claim 38 , wherein the lithium salt is dissolved in an organic carbonate.

40. The electrical storage device of claim 38 , wherein the electrical storage device comprises a cell, a battery pack, a secondary battery, a capacitor, or a supercapacitor.