CN113519074A - 干式电极制造 - Google Patents
干式电极制造 Download PDFInfo
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- CN113519074A CN113519074A CN201980093524.0A CN201980093524A CN113519074A CN 113519074 A CN113519074 A CN 113519074A CN 201980093524 A CN201980093524 A CN 201980093524A CN 113519074 A CN113519074 A CN 113519074A
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Abstract
本发明涉及一种用于干式制造电极的工艺，所述工艺包括步骤：(1)提供基底，(2)将底漆材料分配到基底上以便在基底上提供底漆层，(3a)将电极材料分配到底漆层上并且(3b)借助压力和/或温度附接所述电极材料以便提供电极材料层。
Description
技术领域
本发明涉及一种用于干式制造电极的工艺。
背景技术
现有技术的锂离子电池的电极通过用活性材料浆体湿式涂覆传导性基底制造。也研究了通过用活性材料干式涂覆具有底漆层的基底以制备电极。然而必要的是为基底涂覆底漆层以确保干式涂覆的活性材料的附着性。底漆层附加地改善了传导性和基底与活性材料之间的电阻特性并且进一步还充当着基底的保护屏障。
底漆层包括传导性的碳材料、例如石墨和碳黑。底漆层在单独的工艺中通过用浆体湿式涂覆基底制备，所述浆体包括底漆材料、溶剂和粘合剂。具有底漆层的基底的制备由US 6,627,252 B1已知。
然而，具有底漆层的基底的制备需要附加的、单独的工艺步骤，所述工艺步骤不能与接下来的活性材料的干式涂覆步骤兼容，因此使得难以集成两个工艺步骤并且底漆层需要单独地制备。
因此，本发明所要解决的技术问题在于，提供一种用于制备具有薄底漆层的电极的改善的工艺，所述工艺在时间和成本方面更高效、更环境友好、需要更少的空间和更少的工艺步骤并且能够被集成到用于干式涂覆活性材料的设备中。
发明内容
该技术问题已经令人惊讶地通过按照本发明的用于干式制造电极的工艺解决，所述工艺包括步骤：
(1)提供基底，
(2)将底漆材料分配到基底上以便在基底上提供底漆层，
(3a)将电极材料分配到底漆层上并且
(3b)借助压力和/或温度附接所述电极材料以便提供电极材料层。
已经令人惊讶地发现，可以通过将底漆材料分配到基底上形成底漆层。这个新工艺步骤尤其不需要首先制备底漆材料、粘合剂和溶剂的浆体并且随即将所述浆体施加在基底板的一个表面上、通过加热干燥浆体并且随即在基底板的第二表面上重复这些步骤。
本发明的工艺允许将涂覆底漆材料和涂覆活性材料的步骤包含在一个工艺单元中。现有技术的工艺附加地需要将具有底漆层的基底卷起以运输至不同的工艺设备中并且接下来展开。因此，本发明的工艺更高效。进一步地，本发明的工艺更环境友好，因为没有使用潜在有害的溶剂、例如丙酮或者N-甲基-2-吡咯烷酮(NMP)。
在其它的实施方式中，本发明涉及一种能够通过本发明的工艺获得的电极。
在另外的实施方式中，本发明涉及一种能量存储设备，其包括能够通过本发明的工艺获得的电极。
附图说明
图1示出本发明的一种实施方式。基底板(10)沿箭头方向移动经过不同的步骤。首先，通过从电容器极板(18)的静电沉积使底漆材料(20)沉积在第一基底表面(12)上，以形成第一底漆层(22)。基底通过转向辊(30)被转向并且接下来使底漆材料沉积在第二基底表面(14)上，以形成第二底漆层(24)。随即通过两对压光辊(32)将电极材料(40)同时地分配到并且附接到/纤维化到第一和第二底漆层(22、24)上。可选地，电极材料层(40)还通过一对附加的反向旋转的压光辊(34)压紧。
在图2中，通过从电容器极板(18)的静电沉积使底漆材料(20)沉积在第一基底表面(12)上并且随即通过一对压光辊(36)压紧，以形成第一底漆层(22)。基底通过转向辊(30)被转向并且接下来使底漆材料(20)沉积在第二基底表面(14)上，并且随即通过一对压光辊(36)压紧，以形成第二底漆层(24)。随即通过两对压光辊(32)将电极材料(40)同时地分配到并且附接到/纤维化到第一和第二底漆层(22、24)上。可选地，电极材料层(40)还通过一对附加的反向旋转的压光辊(34)压紧。
图3示出包括电喷涂沉积的工艺。底漆材料(20)通过电喷涂沉积装置(16)同时地沉积在第一基底表面(12)和第二基底表面(14)上并且随即可选地通过一对压光辊(36)压紧，以形成第一和第二底漆层(22、24)。随即通过两对压光辊(32)将电极材料(40)同时地分配到并且附接到/纤维化到第一和第二底漆层(22、24)上。可选地，电极材料层(40)还通过一对附加的反向旋转的压光辊(34)压紧。
具体实施方式
以下的定义与本发明的实施方式相结合地是重要的。
基底是传导性的材料。非限制性的基底示例为包括铝、铜、镍和/或钛的组合物。基底优选由铝组成，因为铝具有高强度和良好的传导性。基底可以具有任何形状，但通常以板或者薄片的形式提供。基底也可以形式为絮状材料或者泡沫金属材料。这些板的厚度约为4至30μm。比4μm薄得多的薄片易损坏、难以制造并且具有升高的电阻。
术语“包括”的含义应理解为包含所有专门提到的特征以及可选的、附加的、未说明的特征，而术语“由…组成”只包含那些所说明的特征。因此，“包括”包含了通过“由…组成”说明的组合物作为限定性的情况。
在此使用的表述“干式制造电极”涉及的工艺使用干式涂覆以制备底漆层和电极材料层。与湿式涂覆不同，相关的颗粒并不是首先被溶解或者分散在溶剂中，而是直接被分配。因此，干式制造涉及这样的工艺，在所述工艺中不使用或者基本上不使用溶剂。尽管如此，需要理解的是即使在干式制造电极期间，材料也可能含有一些作为来自环境的杂质或者吸附物的残余的溶剂和/或水分。
表述“借助压力和/或温度附接”也包括用电极材料层压具有底漆层的基底，其中，电极材料主要通过第二粘合剂的纤维化(fibrillization)附接。在本申请的背景中，术语“压力”应理解为包括剪切力。
在此使用的术语“分配”和其变型术语应以较宽的方式理解为包括沉积、流延、涂覆、层压、喷涂等施加方法。
以下定义按照本发明的优选实施方式。优选实施方式优选是单独的或者组合的。此外，应该理解的是以下的优选实施方式涉及本发明的所有方面，也就是用于制备电极的工艺、能够通过这种工艺获得的电极和包括所述电极的能量存储设备。
在一种实施方式中，所述底漆材料作为固态颗粒通过静电沉积、优选通过从电容器极板的沉积或者通过静电喷涂被分配。在特别优选的实施方式中，底漆材料通过电晕分配装置或者摩擦电分配装置分配。
静电沉积是一种用于沉积薄的颗粒层的技术，其通过颗粒的电离、例如通过电晕电离或者通过摩擦电的摩擦实现。颗粒随即被沉积在基底上。与例如等离子体增强的化学气相沉积(PECVD)不同，颗粒以固态形式沉积。在一种优选的实施方式中，通过静电喷涂沉积(ESD)实现沉积。ESD涉及底漆材料的带电气溶胶的形成，所述带电气溶胶随即通过电场向基底导引。
在更优选的实施方式中，从电容器极板进行沉积。
在一种实施方式中，所述底漆层具有10nm至5μm、优选0.05μm至1μm的厚度。原则上，底漆层厚度可以小到底漆颗粒的一个颗粒层。在一种实施方式中，层厚为10nm至5μm，10nm至4μm，10nm至3μm，10nm至2μm，10nm至1μm，10nm至0.1μm。在其它的实施方式中，层厚为50nm至5μm，0.1μm至5μm，1μm至5μm。层厚优选小于5μm。更优选的是，底漆层具有10nm至1μm的厚度。在特别优选的实施方式中，底漆层具有0.1至1μm的厚度。需要注意的是，底漆层的厚度指的是获得的电极的厚度。
在一种实施方式中，所述底漆材料从由石墨、碳黑、石墨烯、碳纳米管、富勒烯、第一粘合剂和它们的混合物组成的组中选择。在一种优选的实施方式中，底漆材料包括石墨和/或碳黑。在一种实施方式中，底漆材料包括50至100重量％的碳材料和0至50重量％的第一粘合剂，所述碳材料从由石墨、碳黑、石墨烯、碳纳米管、富勒烯和它们的混合物组成的组中选择。在一种优选的实施方式中，底漆材料包括70至100重量％的碳材料和0至30重量％的第一粘合剂，所述碳材料从由石墨、碳黑、石墨烯、碳纳米管、富勒烯和它们的混合物组成的组中选择。在其它的实施方式中，底漆材料不包含粘合剂。
第一粘合剂包括聚合物粘合剂。适当的聚合物粘合剂是聚乙烯(PE)、甲基纤维素、含氟弹性体、聚(醋酸乙烯酯)、聚氨酯、聚(丙烯酸)、聚(甲基丙烯酸)和它们的混合物。含氟弹性体的非限制性的示例包括聚偏二氟乙烯(PVdf)、聚四氟乙烯(PTFE)和聚六氟丙烯。聚合物可以是单聚物或者共聚物。共聚物包括统计共聚物、梯度共聚物、交替共聚物、嵌段共聚物和分支共聚物。第一粘合剂优选包括聚偏二氟乙烯和/或聚四氟乙烯(PTFE)。第一粘合剂特别优选包括聚偏二氟乙烯。
在一种实施方式中，所述底漆材料具有1至500nm、优选10至300nm、更优选50至200nm的平均颗粒尺寸(D50)。在一种实施方式中，底漆材料具有1至400nm、1至300nm、1至200nm、10至500nm、10至400nm、10至300nm、10至200nm、10至100nm、50至500nm、50至400nm、50至300nm或者50至200nm的平均颗粒尺寸(D50)。颗粒尺寸优选为50至200nm。颗粒尺寸可以通过激光衍射、例如ISO 13320:2009或者动态光散射的方法确定。上述底漆材料的颗粒尺寸指的是初级颗粒尺寸。然而，初级颗粒也可以形成具有不超过2μm的次级颗粒尺寸的聚集体。
在一种实施方式中，所述电极材料包括活性材料、第二粘合剂和/或添加剂。在一种实施方式中，电极材料包括60至100重量％的活性材料和0至30重量％的第二粘合剂和0至10重量％的添加剂。在一种优选的实施方式中，电极材料包括90至100重量％的活性材料和0至10重量％的第二粘合剂。
适当的活性材料在“Principles and Applications of Lithium Batteries”，J.Park，第一版，2012，Wiley-VCH出版社和“Handbook of Battery Materials”，C.Daniel，J.Besenhard，第二版，2011，Wiley-VCH出版社中公开。活性材料可以是阳极或者阴极活性材料。活性材料优选是阴极活性材料。
阳极活性材料可以被划分为基于嵌入的材料例如石墨、基于转换反应的材料和基于合金化反应的材料。
阴极活性材料可以被划分为层状结构化合物、尖晶石和反尖晶石复合材料、橄榄石复合材料、钒复合材料和它们的混合物。
层状结构化合物的非限制性的示例包括LCO(LiCoO2)、LNO(LiNiO2)、LMO(LiMnO2)、LTO(Li3-xMxN；M＝Co、Ni or Cu、0.1<x<0.6)、LiFeO2、NMC(Ni-Mn-Co三组分系统、例如Li[NixMnxCo1-2x]O2、0<x<0.5、优选LiNi1/3Mn1/3Co1/3O2(NMC 333)和NCA(Ni-Mn-Al三组分系统、例如LiNi0.8Co0.15Al0.05)。此外，NMC的非限制性的示例包括LiNi8/10Mn1/10Co1/10O2(NMC 811)、LiNi9/10Mn0.5/10Co0.5/10O2(NMC 9/0.5/0.5)和LiNi6/10Mn2/10Co2/10O2(NMC 622)。在优选的实施方式中，电极活性材料包括NMC 622。
尖晶石和反尖晶石复合材料的非限制性的示例包括LMO(LiMn2O4)、LiTi2O4、LiV2O4和LiNiVO4。
橄榄石复合材料的非限制性的示例包括LFP(LiFePO4)和LiFe1-xMxPO4(0<x<1；M＝Mn、Co、Ni)。
钒复合材料的非限制性的示例包括V2O5、V2O3、VO2、V6O13、V4O9、V3O7、Ag2V4O11、AgVO3、Li3V3O5、δ-NH4V4O10、Mn0.8V7O16、LiV3O8、CuxV2O5(0<x<0.3)和CrxV6O13(0<x<0.1)。
在优选的实施方式中，活性材料包括NCA、LCO、LNO、NMC、LTO、LMO或者它们的混合物。以上复合材料的优选混合物是NMC-LMO混合物。
第二粘合剂包括聚偏二氟乙烯(PVdf)、聚六氟丙烯、聚四氟乙烯(PTFE；
)、聚乙烯(PE)或者它们的混合物或者共聚物。在一种优选的实施方式中，第二粘合剂是聚四氟乙烯。
添加剂是传导性的碳。在一种优选的实施方式中，添加剂由石墨、碳黑、碳纳米管、石墨烯、富勒烯和它们的混合物组成。在一种优选的实施方式中，添加剂包括石墨和/或碳黑。在其它的实施方式中，所述电极材料层具有3.0至4.0g/cm3、优选3.2至3.8g/cm3的密度。
在其它的实施方式中，所述电极材料层具有50至200μm的厚度。在其它的实施方式中，所述电极材料层具有20至500μm、30至400μm或者40至300μm的厚度。在优选的实施方式中，所述电极材料层具有70至300μm的厚度。在特别优选的实施方式中，所述电极材料层具有70至150μm的厚度。如果存在第一电极材料层和第二材料层，则以上的厚度也分别适用于第一和第二电极材料层。需要注意的是，电极材料层的厚度指的是所获得的电极中的厚度。
在一种实施方式中，步骤(2)还包括借助压力和/或温度、优选通过用压光辊或者反压辊的滚压将所述底漆材料附接到基底的步骤(2’)。
在一种实施方式中，步骤(3b)包括通过辊、优选使用压光辊或者反压辊附接电极材料。
在其它的实施方式中，基底包括第一和第二表面，并且将底漆材料同时地或者依次地分配到第一和第二表面上，以便获得第一和第二底漆层。基底通常被提供为具有第一和第二表面的薄板、薄片、絮状材料或者泡沫金属(expanded metal)。通过按照本发明的工艺能够在第一和第二表面上同时形成底漆层。然而，也能够在第一表面上形成第一底漆层并且随即依次地在第二表面上形成第二底漆层。
相同地适用于电极材料层的形成。在一种实施方式中，
(3a)将所述电极材料同时地分配到第一和第二底漆层上，并且
(3b)将所述电极材料同时地附接到第一和第二底漆层。
因此形成第一电极材料层和第二电极材料层。
在一种实施方式中，所述工艺包括步骤：
(3c)附加地压紧(一个或多个)电极材料层。所述附加的压紧可以通过压光辊或者反压辊进行。所述附加的压紧步骤可以确保实现最佳的电极材料层密度。如上所述地，3.2至3.8g/cm3的密度是优选的。
在一种实施方式中，步骤(3a)和(3b)依次地或者同时地进行。分配电极材料和附接电极材料可以同时地进行。然而，也能够首先在底漆层上分配电极材料层并且随即依次地附接电极材料。
在一种实施方式中，所述工艺是连续的工艺。为了效率的目的，所有步骤优选以连续的方式进行。
在一种实施方式中，所述基底是具有5至30μm的厚度的铝板。在一种优选的实施方式中，所述基底是具有8至15μm的厚度的铝板。
在一种实施方式中，电极是锂离子电池的电极。在一种实施方式中，电极是阴极。所述电极优选是锂离子电池的阴极。
Claims (15)
1.一种用于干式制造电极的工艺，所述工艺包括步骤：
(1)提供基底，
(2)将底漆材料分配到基底上以便在基底上提供底漆层，
(3a)将电极材料分配到底漆层上并且
(3b)借助压力和/或温度附接所述电极材料以便提供电极材料层。
2.按权利要求1所述的工艺，其中，所述底漆材料作为固态颗粒通过静电沉积、优选通过从电容器极板的沉积或者通过静电喷涂被分配。
3.按权利要求1或2所述的工艺，其中，所述底漆层具有10nm至5μm、优选0.05μm至1μm的厚度。
4.按权利要求1至3中的任一项所述的工艺，其中，所述底漆材料从由石墨、碳黑、石墨烯、碳纳米管、富勒烯、第一粘合剂和它们的混合物组成的组中选择。
5.按权利要求1至4中的任一项所述的工艺，其中，所述底漆材料具有1至500nm、优选10至300nm、更优选50至200nm的平均颗粒尺寸(D50)。
6.按权利要求1至5中的任一项所述的工艺，其中，所述电极材料包括活性材料、第二粘合剂和/或添加剂。
7.按权利要求1至6中的任一项所述的工艺，其中，所述电极材料层具有3.0至4.0g/cm3、优选3.2至3.8g/cm3的密度。
8.按权利要求1至7中的任一项所述的工艺，其中，所述电极材料层具有50至200μm的厚度。
9.按权利要求1至8中的任一项所述的工艺，其中，步骤(2)还包括借助压力和/或温度、优选通过用压光辊或者反压辊的滚压将所述底漆材料附接到基底的步骤(2’)。
10.按权利要求1至9中的任一项所述的工艺，其中，步骤(3b)包括通过辊、优选使用压光辊或者反压辊附接电极材料。
11.按权利要求1至10中的任一项所述的工艺，其中，基底包括第一和第二表面，并且将底漆材料同时地或者依次地分配到第一和第二表面上，以便获得第一和第二底漆层。
12.按权利要求11所述的工艺，其中，
(3a)将所述电极材料同时地分配到第一和第二底漆层上，并且
(3b)将所述电极材料同时地附接到第一和第二底漆层。
13.按权利要求1至12中的任一项所述的工艺，其中，所述基底是具有5至30μm的厚度的铝板。
14.一种能够通过按权利要求1至13中的任一项所述的工艺获得的电极。
15.一种能量存储设备，包括按权利要求14所述的能够通过按权利要求1至13中的任一项所述的工艺获得的电极。
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| PCT/EP2019/082096 WO2021098963A1 (en) | 2019-11-21 | 2019-11-21 | Dry electrode manufacturing |
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| US (1) | US20220399539A1 (zh) |
| EP (1) | EP4062467A1 (zh) |
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| US20220399539A1 (en) | 2022-12-15 |
| EP4062467A1 (en) | 2022-09-28 |
| WO2021098963A1 (en) | 2021-05-27 |
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