RECYCLED ALUMINUM ALLOYS FOR USE IN CURRENT COLLECTORS IN LITHIUM-ION BATTERIES
Described are battery components including a current collector and a coating layer disposed over at least a portion of a surface of the current collector. The current collector can include a recycled content aluminum alloy. In some examples, the current collector can include from 50% to 100% recycled aluminum content. The recycled content aluminum alloy may be, for example, a 3xxx series aluminum alloy or a 5xxx series aluminum alloy.
1 . A battery component, comprising:
a current collector comprising a recycled content aluminum alloy; and
a coating layer disposed over at least a portion of a surface of the current collector.
2 . The battery component of claim 1 , wherein the current collector comprises from 50% to 100% recycled aluminum content.
3 . The battery component of claim 1 , wherein the current collector comprises a 3xxx series aluminum alloy or a 5xxx series aluminum alloy.
4 . The battery component of claim 1 , wherein the current collector has a thickness from 0.005 mm to 0.5 mm.
5 . (canceled)
6 . The battery component of claim 1 , wherein the current collector comprises a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.
7 . The battery component of claim 1 , wherein the current collector comprises from 50 wt. % to 99.9 wt. % Al.
8 . (canceled)
9 . The battery component of claim 1 , wherein the coating layer comprises a carbonaceous material.
10 . The battery component of claim 9 , wherein the carbonaceous material comprises a carbon black material or a Ketjenblack material.
11 . The battery component of claim 1 , wherein the coating layer has a thickness of from 5 nm to 100 μm.
12 . The battery component of claim 1 , wherein the coating layer completely coats the surface of the current collector or wherein the coating layer partially coats the surface of the current collector.
13 . The battery component of claim 1 , wherein the coating layer comprises a multilayer coating.
14 . The battery component of claim 1 , wherein one or more characteristics of the current collector are modified in a metal coating process to generate the coating layer over at least a portion of the surface of the current collector, and wherein the one or more characteristics of the current collector comprise a surface area of the current collector, a surface roughness of the current collector, a surface oxide layer, electrical conductivity, thermal conductivity, corrosion resistance, chemical reactivity, electrolyte reactivity, active material reactivity, wetting character, or adhesion character.
15 . The battery component of claim 14 , wherein the electrical conductivity of the current collector is from 30% IACS to 65% IACS.
16 . A method of making a battery component, the method comprising:
providing a current collector, wherein the current collector comprises a recycled content aluminum alloy; and
subjecting a surface of the current collector to a coating process to generate a coating layer over at least a portion of the surface of the current collector.
17 . The method of claim 16 , wherein the coating process modifies one or more surface characteristics of the current collector.
18 . The method of claim 17 , wherein the one or more surface characteristics of the current collector comprise a surface area of the current collector, a surface roughness of the current collector, a surface oxide layer, electrical conductivity, thermal conductivity, corrosion resistance, chemical reactivity, electrolyte reactivity, active material reactivity, wetting character, or adhesion character.
19 . The method of claim 16 , further comprising:
subjecting the current collector or the coating layer to a further coating process to form a conductive layer, wherein the conductive layer comprises one or more of a carbonaceous material or a binder.
20 . (canceled)
21 . The method of claim 16 , further comprising:
subjecting the current collector and coating layer to a further coating process to form an electrode active material layer over the coating layer.
22 . The method of claim 16 , wherein the coating process comprises plasma-assisted physical vapor deposition, plasma-activated physical vacuum deposition, plasma spray physical vapor deposition, vacuum plasma spraying, metal gun-spray deposition, plasma spraying, plasma transferred wire arc spraying, cold spraying, electro-chemical deposition, chemical deposition, sputtering, dip coating, an immersion coating process, a roll-to-roll coating process, or any combination thereof.
23 . (canceled)
24 . (canceled)
25 . A battery comprising the battery component of claim 1 .
26 . (canceled)