Water soluble paa-based polymer blends as binders for si dominant anodes

Abstract

Systems and methods utilizing water soluble (aqueous) PAA-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 pyrolyzed water soluble PAA-based polymer blend, wherein the water soluble PAA-based polymer blend comprises PAA and one or more additional water-soluble polymer components. 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 formed from an electrode slurry comprising silicon and a water soluble PAA-based polymer blend, wherein said water soluble PAA-based polymer blend comprises PAA and one or more additional water-soluble polymer components;   wherein said one or more additional water-soluble polymer components comprises a polymer containing one or more functional groups selected from the group consisting of —OH, NH—, NH2, and —COOH; and   wherein said electrode slurry has a slurry viscosity of 1500-2000 cps.   
     
     
         2 . The electrode according to  claim 1 , wherein one of said one or more additional water-soluble polymer components is phenolic resin. 
     
     
         3 . The electrode according to  claim 2 , wherein the concentration of said phenolic resin in the water soluble PAA-based polymer blend is <30 wt. % 
     
     
         4 . The electrode according to  claim 1 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA and two additional water-soluble polymer components. 
     
     
         5 . The electrode according to  claim 4 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA, phenolic resin and a third water-soluble polymer component. 
     
     
         6 . The electrode according to  claim 1 , wherein the electrode coating layer further comprises conductive additives. 
     
     
         7 . The electrode 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. 
     
     
         8 . The electrode according to  claim 1 , wherein the electrode coating layer comprises more than 70% silicon. 
     
     
         9 . 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. 
     
     
         10 . The electrode according to  claim 1 , wherein the battery electrode is in a lithium ion battery. 
     
     
         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 soluble PAA-based polymer blend and Si powder;   fabricating a battery electrode by coating the slurry on a current collector; and   pyrolyzing said electrode coating layer;   wherein said water soluble PAA-based polymer blend comprises PAA and one or more additional water-soluble polymer components;   wherein said one or more additional water-soluble polymer components comprises a polymer containing one or more functional groups selected from the group consisting of —OH, NH—, NH2, and —COOH; and   wherein said electrode slurry has a slurry viscosity of 1500-2000 cps.   
     
     
         12 . The method of  claim 11 , wherein one of said one or more additional water-soluble polymer components is phenolic resin. 
     
     
         13 . The method of  claim 12 , wherein the concentration of said phenolic resin in the water soluble PAA-based polymer blend is <30 wt. % 
     
     
         14 . The method of  claim 11 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA and two additional water-soluble polymer components. 
     
     
         15 . The method of  claim 14 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA, phenolic resin and a third water-soluble polymer component. 
     
     
         16 . The method according to  claim 11 , wherein the electrode coating layer further comprises conductive additives. 
     
     
         17 . 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. 
     
     
         18 . The method according to  claim 11 , wherein the electrode coating layer comprises more than 70% silicon. 
     
     
         19 . 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. 
     
     
         20 . A battery, the battery comprising:
 a cathode, a separator, an electrolyte, and an anode, the anode comprising an electrode coating layer on a current collector, the electrode coating layer formed from an electrode slurry comprising silicon and a pyrolyzed water soluble PAA-based polymer blend, wherein said water soluble PAA-based polymer blend comprises PAA and one or more one or more additional water-soluble polymer components;   wherein said one or more additional water-soluble polymer components comprises a polymer containing one or more functional groups selected from the group consisting of —OH, NH—, NH2, and —COOH; and   wherein said electrode slurry has a slurry viscosity of 1500-2000 cps.   
     
     
         21 . The battery of  claim 20 , wherein one of said one or more additional water-soluble polymer components is phenolic resin. 
     
     
         22 . The battery of  claim 21 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA and two additional water-soluble polymer components. 
     
     
         23 . The battery of  claim 22 , wherein said water soluble PAA-based polymer blend is a tertiary system comprising PAA, phenolic resin and a third water-soluble polymer component.