Method and system for pulverization mitigation additives for silicon dominant anodes

Abstract

Systems and methods for pulverization mitigation additives for silicon dominant anodes may include an electrode including a metal current collector and an active material layer on the current collector. The active material layer may include islands of material separated by cracks, with the islands including, at least, silicon and conductive additives. At least a portion of the additives may extend from within the islands and bridge the cracks of the active material layer. The conductive additives may form a structure providing electrical conductivity between a first island and a second island, or between at least one island and the metal current collector. The additives may include between 1% and 40% of the active material layer. The active material layer may include between 20% to 95% silicon. The conductive additives may include carbon nanotubes and/or graphene sheets.

1 - 21 . (canceled) 
     
     
         22 . A battery electrode, the electrode comprising:
 a metal current collector; and   an active material layer on the current collector;   wherein the active material layer comprises islands of material separated by cracks, the islands comprising silicon and conductive additives;   wherein at least a portion of the conductive additives extend from within the islands and bridge the cracks of the active material layer; and   wherein the conductive additives form a structure providing electrical conductivity between a first island and a second island, or between at least one island and the metal current collector.   
     
     
         23 . The electrode according to  claim 22 , wherein the conductive additives comprise between 1% and 40% of the active material layer. 
     
     
         24 . The electrode according to  claim 22 , wherein the active material layer comprises between 20% to 95% silicon. 
     
     
         25 . The electrode according to  claim 22 , wherein the conductive additives comprise carbon nanotubes and/or graphene sheets. 
     
     
         26 . The electrode according to  claim 22 , wherein the conductive additives comprise metal. 
     
     
         27 . The electrode according to  claim 26 , wherein the metal comprises one or more of: gallium, indium, copper, aluminum, lead, tin, nickel. 
     
     
         28 . The electrode according to  claim 26 , wherein the metal comprises a transition metal. 
     
     
         29 . The electrode according to  claim 22 , wherein the conductive additives comprise one or more semiconductors. 
     
     
         30 . The electrode according to  claim 22 , wherein the conductive additives comprise long narrow filaments with an aspect ratio of 20 or greater. 
     
     
         31 . The electrode according to  claim 22 , wherein the cracks form after one or more formation processes and/or one or more lithiation/delithiation cycles of a battery incorporating the electrode. 
     
     
         32 . The electrode according to  claim 22 , wherein islands adjacent to a particular crack have mirror image surfaces facing the particular crack. 
     
     
         33 . A method of forming an electrode, the method comprising:
 providing a metal current collector; and   providing an active material layer on the current collector;   wherein the active material layer comprises islands of material separated by cracks, the islands comprising silicon and conductive additives;   wherein at least a portion of the conductive additives extend from within the islands and bridge the cracks of the active material layer; and   wherein the conductive additives form a structure providing electrical conductivity between a first island and a second island, or between at least one island and the metal current collector.   
     
     
         34 . The method according to  claim 33 , wherein the conductive additives comprise between 1% and 40% of the active material layer. 
     
     
         35 . The method according to  claim 33 , wherein the active material layer comprises between 20% to 95% silicon. 
     
     
         36 . The method according to  claim 33 , wherein the conductive additives comprise carbon nanotubes and/or graphene sheets. 
     
     
         37 . The method according to  claim 33 , wherein the conductive additives comprise metal. 
     
     
         38 . The method according to  claim 37 , wherein the metal comprises one or more of: gallium, indium, copper, aluminum, lead, tin, nickel. 
     
     
         39 . The method according to  claim 37 , wherein the metal comprises a transition metal. 
     
     
         40 . The method according to  claim 33 , wherein the conductive additives comprise one or more semiconductors. 
     
     
         41 . The method according to  claim 33 , wherein the conductive additives comprise long narrow filaments with an aspect ratio of 20 or greater. 
     
     
         42 . The method according to  claim 33 , wherein the cracks form after one or more formation processes and/or one or more lithiation/delithiation cycles of a battery incorporating the electrode. 
     
     
         43 . The method according to  claim 33 , wherein islands adjacent to a particular crack have mirror image surfaces facing the particular crack. 
     
     
         44 . A battery, the battery comprising:
 a battery comprising a cathode, an electrolyte, and an anode comprising a metal current collector and an active material layer on the current collector;   wherein the active material layer comprises: islands of material separated by cracks, the islands comprising silicon and conductive additives;   wherein at least a portion of the conductive additives extend from within the islands and bridge the cracks of the active material layer; and   wherein the conductive additives form a structure providing electrical conductivity between a first island and a second island, or between at least one island and the metal current collector.