Method and system for all-conductive battery electrodes
Systems and methods for all-conductive battery electrodes may include an electrode coating layer on a current collector, where the electrode coating layer comprises more than 50% silicon, and where each material in the electrode has a resistivity of less than 100 Ω-cm. The silicon may have a resistivity of less than 10 Ω-cm, less than 1 Ω-cm, or less than 1 mΩ-cm. The electrode coating layer may comprise pyrolyzed carbon and/or conductive additives. The current collector comprises a metal foil. The metal 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 comprises more than 70% silicon. The electrode may be in electrical and physical contact with an electrolyte. The electrolyte may comprise a liquid, solid, or gel. The battery electrode may be in a lithium ion battery.
1. A battery electrode, comprising:
a current collector; and
an electrode coating layer on the current collector;
wherein the electrode coating layer comprises a binder material and more than 50% silicon; and
wherein a difference in resistivity between the binder material and the silicon of the more than 50% silicon is less than 100 Ω-cm.
2. The battery electrode of claim 1 , wherein:
the resistivity of the binder material is less than 10 Ω-cm; and
the resistivity of the silicon of the more than 50% silicon is less than 10 Ω-cm.
3. The battery electrode of claim 1 , wherein:
the resistivity of the binder material is less than 1 Ω-cm; and
the resistivity of the silicon of the more than 50% silicon is less than 1 Ω-cm.
4. The battery electrode of claim 1 , wherein:
the resistivity of the binder material is less than 1 mΩ-cm; and
the resistivity of the silicon of the more than 50% silicon is less than 1 mΩ-cm.
5. The battery electrode of claim 1 , wherein the binder material comprises pyrolyzed carbon.
6. The battery electrode of claim 1 , wherein the electrode coating layer comprises conductive additives.
7. The battery electrode of claim 1 , wherein the current collector comprises a metal foil.
8. The battery electrode of 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.
9. The battery electrode of claim 1 , wherein the electrode coating layer comprises more than 70% silicon.
10. The battery electrode of claim 1 , wherein each material in the battery electrode has a resistivity of less than 100 Ω-cm.
11. The battery electrode of claim 1 , wherein the binder material provides a structural framework around silicon particles of the more than 50% silicon.
12. A method of forming a battery electrode, the method comprising:
mixing a binder material and silicon to form a slurry; and
forming, from the slurry, an electrode coating layer on a current collector;
wherein the electrode coating layer comprises the binder material and more than 50% silicon; and
wherein a difference in resistivity between the binder material and the silicon of the more than 50% silicon is less than 100 Ω-cm.
13. The method of claim 12 , wherein:
the resistivity of the binder material is less than 10 Ω-cm; and
the resistivity of the silicon of the more than 50% silicon is less than 10 Ω-cm.
14. The method of claim 12 , wherein:
the resistivity of the binder material is less than 1 Ω-cm; and
the resistivity of the silicon of the more than 50% silicon is less than 1 Ω-cm.
15. The method of claim 12 , wherein:
the resistivity of the binder material is less than 1 mΩ-cm; and
the resistivity of the silicon of the more than 50% silicon is less than 1 mΩ-cm.
16. The method of claim 12 , wherein the binder material comprises pyrolyzed carbon.
17. The method of claim 12 , wherein the electrode coating layer comprises conductive additives.
18. The method of claim 12 , wherein the current collector comprises a metal foil.
19. The method of claim 12 , wherein the current collector comprises one or more of a copper, tungsten, stainless steel, or nickel foil in electrical contact with the electrode coating layer.
20. The method of claim 12 , wherein the electrode coating layer comprises more than 70% silicon.
21. A battery, comprising:
a cathode, a separator, an electrolyte, and an anode;
wherein the anode comprises a current collector and an electrode coating layer on the current collector;
wherein the electrode coating layer comprises a binder material and more than 50% silicon; and
wherein a difference in resistivity between the binder material and the silicon of the more than 50% silicon is less than 100 Ω-cm.
22. The battery of claim 21 , wherein:
the anode is in electrical and physical contact with the electrolyte; and
the electrolyte comprises a liquid, solid, or gel.