WO2026010929A1 - Clad aluminum alloy foil having high recycled content and high electrical conductivity - Google Patents

Abstract

Disclosed herein are high recycled content clad aluminum alloy products that exhibit high electrical conductivity and methods for preparing the same. More particularly, disclosed are clad aluminum alloy products that are produced from at least two aluminum alloys selected from different aluminum alloy series and that exhibit good electrical conductivity despite being produced from less primary aluminum than conventional 1xxx series aluminum alloys. The clad aluminum alloy products can be used in electrochemical applications, including as current collectors in batteries.

Description

CLAD ALUMINUM ALLOY FOIL HAVING HIGH RECYCLED CONTENT AND HIGH ELECTRICAL CONDUCTIVITY

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/666,810, filed July 2, 2024, which is hereby incorporated by reference in its entirety for all intents and purposes.

FIELD

[0002] The present disclosure relates to the fields of material science, material chemistry, metallurgy, aluminum alloys, aluminum alloy products, aluminum fabrication, and related fields. More specifically, the disclosure relates to clad aluminum alloys that are produced using aluminum alloys selected from different aluminum alloy series and that have high recycled content and exhibit high electrical conductivity. The clad aluminum alloy products can be used in a variety of applications including, for example, as electrode current collectors used in battery applications.

BACKGROUND

[0003] Generally, aluminum alloys used as electrode current collectors in battery applications require high electrical conductivity. For example, an electrode member of a lithium-ion battery includes a positive electrode plate, a separator, and a negative electrode plate. The positive electrode plate may be produced from an aluminum alloy having excellent electrical conductivity and less heat generation without affecting electrical efficiency of the battery. Primary aluminum has a high electrical conductivity thereby providing good conductivity properties. The higher the electrical conductivity, the more easily the electricity is conducted. Aluminum alloys that include high amounts of primary aluminum have higher electrical conductivity values than aluminum alloys that have less primary aluminum. Therefore, Ixxx series aluminum alloys are generally used to produce electrode current collectors. Additionally, aluminum alloys that include high amounts of solute elements typically have lower electrical conductivity than aluminum alloys that include fewer solute elements. As a result, aluminum alloys used for producing parts in battery applications are often produced from aluminum alloys including a high content of primary aluminum (e.g., greater than 99% primary aluminum) due to the high amounts of primary aluminum that provide good electrical conductivity and corrosion resistance properties.

[0004] There has been an interest in using recycled aluminum alloy materials for producing aluminum alloys used in battery applications. However, recycled aluminum alloy materials may be unsuitable for use in preparing high performance aluminum alloys, as the recycled aluminum alloy materials may contain high levels of certain undesirable elements that adversely affect the electrical conductivity properties of an aluminum alloy. Consequently, it is not practical to use high amounts of recycled aluminum alloy materials for producing aluminum alloys for use as electrode current collectors, without negatively impacting desirable alloy properties.

SUMMARY

[0005] The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings and each claim.

[0006] Provided herein are clad aluminum alloy foils having high recycled content and high electrical conductivity. The clad aluminum alloy foils described herein comprise a first layer comprising a first aluminum alloy that has a first electrical conductivity above 50% IACS; and a second layer coupled to the first layer, the second layer comprising a second aluminum alloy including a recycled content of at least 50 wt. %. In some embodiments, the second aluminum alloy is selected from a different aluminum alloy series than the first aluminum alloy. In some embodiments, the first aluminum alloy is a Ixxx series aluminum alloy. In some embodiments, the second aluminum alloy is a 3xxx series aluminum alloy. In other embodiments, the second aluminum alloy is a 6xxx series aluminum alloy.

[0007] In some embodiments, a combined electrical conductivity of the clad aluminum alloy alloys is greater than 40% IACS. In some embodiments, the electrical conductivity of the second aluminum alloy is a second electrical conductivity, and the combined electrical conductivity of the clad aluminum alloys foils is greater than the second electrical conductivity of the second aluminum alloy by at least 40%. In some embodiments, the clad aluminum alloys foils have a thickness ranging from 10 microns to 20 microns.

[0008] In some embodiments, a method of producing a clad aluminum alloy foil is provided. The method includes: providing a first aluminum alloy that has an electrical conductivity above 50% IACS and a second aluminum alloy comprising a recycled content of at least 50 wt. %; and processing the first aluminum alloy and the second aluminum alloy to produce the clad aluminum alloy foil by coupling the first aluminum alloy to the second aluminum alloy. In some embodiments, processing the first aluminum alloy and the second aluminum alloy includes providing a stacked arrangement comprising the first aluminum alloy and the second aluminum alloy; and rolling the stacked arrangement to produce the clad aluminum alloy foil, wherein the first aluminum alloy forms a first layer coupled to a second layer comprising the second aluminum alloy. In some embodiments, providing the first aluminum alloy and the second aluminum alloy includes selecting the second aluminum alloy from a different aluminum alloy series than the first aluminum alloy. In some embodiments, the first aluminum alloy is a Ixxx series aluminum alloy. In some embodiments, the second aluminum alloy is a 3xxx series aluminum alloy. In other embodiments, the second aluminum alloy is a 6xxx series aluminum alloy. In some embodiments, the clad aluminum alloy foils described herein have a thickness ranging from 10 microns to 20 microns.

[0009] Also provided herein are applications of the clad aluminum alloy foils. In some embodiments, a battery includes a cathode current collector produced using the clad aluminum alloy foils described herein. In some embodiments, the cathode current collector has an electrical conductivity greater than 40% IACS. In some embodiments, the battery is a lithium-ion battery.

[0010] Other objects and advantages will be apparent from the following detailed description of non-limiting example.

BRIEF DESCRIPTION OF THE FIGURES

[0011] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0012] FIG. 1 provides a schematic overview of an example method for making a clad aluminum alloy product. [0013] FIG. 2 provides a graph of electrical conductivity versus foil thickness for comparative aluminum alloys and an example clad aluminum alloy product.

DETAILED DESCRIPTION

[0014] Described herein are clad aluminum alloy products that have high amounts of recycled content (e.g., at least 50 wt. %) and still exhibit high electrical conductivity suitable for battery applications. Specifically, the clad aluminum alloy products described herein include at least two aluminum alloys selected from different aluminum alloy series that are coupled to provide suitable electrical conductivity in an electrochemical environment despite including a higher content of solute elements present in recycled aluminum materials. Examples of the solute elements can include Mg, Si, Fe, Cr, Cu, Zn, or Mn.

[0015] Conventionally, higher amounts of solute elements and less primary aluminum in an aluminum alloy composition would result in poor electrical conductivity properties.

Conventional aluminum alloys for energy storage applications, such as Ixxx series aluminum alloys, have a strictly controlled composition to provide suitable electrochemical properties for use in a battery or other types of energy storage. In general, high electrical conductivity and suitable corrosion resistance is required for aluminum alloys incorporated as current collectors or other components of a battery, resulting in conventional current collectors being fabricated from an aluminum alloy including high amounts of primary aluminum, such as Ixxx series aluminum alloys. For example, Ixxx series aluminum alloys typically include a high primary aluminum content of at least 99 wt. % primary aluminum. However, recycled aluminum materials may include Si, Fe, and other impurities in relatively high quantities. Due to the discrepancy between the aluminum alloy composition of conventional aluminum alloys for battery applications and recycled aluminum alloy materials, little or no recycled aluminum alloy materials can be used to produce these conventional aluminum alloys which in turn limits the amount of the recycled aluminum alloy materials that can be used for battery applications.

[0016] The clad aluminum alloy products described herein can incorporate higher amounts of recycled aluminum alloy materials than conventional aluminum alloys for battery applications while achieving electrochemical properties that are useful for battery applications. Specifically, the clad aluminum alloy product can include two aluminum alloys: a first aluminum alloy selected to have an electrical conductivity above 50% IACS and a second aluminum alloy selected to include a recycled content of at least 50 wt. %. In contrast to processing techniques such as doubling, the aluminum alloys used to produce the clad aluminum alloy product can be selected from different aluminum series, for example to impart suitable material properties. Additionally, cladding is not typically implemented with different aluminum alloys to produce a clad foil product (e.g., with a thickness ranging from

10 microns to 20 microns) as described herein. The clad aluminum alloy products described herein can be used in a variety of applications including, for example, as a cathode current collector in energy storage applications that can replace conventional aluminum alloys produced using a high primary aluminum content. By coupling the first aluminum alloy and the second aluminum alloy, the clad aluminum alloy products can enable the use of recycled aluminum materials to reduce primary aluminum content while providing suitable electrical conductivity for use in energy storage applications.

Definitions and Descriptions:

[0017] As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0018] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “Ixxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0019] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0020] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about

11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm. [0021] As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0022] As used herein, a foil generally refers to a thin subset of sheets, such as referring to aluminum alloy products having a thickness less than or about 0.5 mm, less than or about 0.45 mm, less than or about 0.4 mm, less than or about 0.35 mm, less than or about 0.3 mm, less than or about 0.25 mm, less than or about 0.2 mm, less than or about 0.15 mm, less than or about 0.1 mm, or less than or about 0.05 mm.

[0023] Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A TI condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0024] As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi -continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

[0025] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C. As used herein, the meaning of “ambient conditions” can include temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere in between. For example, barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.

[0026] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g., 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Unless stated otherwise, the expression “up to” when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt.%). [0027] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0028] In the following examples, aluminum alloy products and their components may be described in terms of their elemental composition in weight percent (wt.%). In each alloy, the remainder is aluminum, with a maximum wt.% of 0.15% for the sum of all impurities.

[0029] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.

[0030] Unavoidable impurities, including materials or elements may be present in an alloy in minor amounts due to inherent properties of aluminum or leaching from contact with processing equipment. Some alloys, as described, may contain no more than about 0.25 wt.% of any element besides the alloying elements, incidental elements, and unavoidable impurities.

Clad Aluminum Alloy Products

[0031] The clad aluminum alloy products described herein can be produced using suitable methods. For example, aluminum alloys may be cast, homogenized, hot-rolled, cold- rolled, heat treated, formed, or the like to generate aluminum alloy products. In general, the clad aluminum alloy products described herein can be produced by processing a first aluminum alloy and a second aluminum alloy to couple or attach the first aluminum alloy to the second aluminum alloy.

[0032] FIG. 1 provides an overview of an example method of making a clad aluminum alloy product 105. As shown, a first aluminum alloy and a second aluminum alloy can be provided such that a first layer 110 including the first aluminum alloy is positioned adjacent to a second layer 115 including the second aluminum alloy in a stacked arrangement. In some embodiments, the first aluminum alloy can be selected from a first aluminum alloy series that is different from a second aluminum alloy series from which the second aluminum alloy is selected.

[0033] For example, the first aluminum alloy of the first layer 110 may be a Ixxx series aluminum alloy, whereas the second aluminum alloy of the second layer 115 may be a 3xxx series aluminum alloy. By way of non-limiting example, exemplary Ixxx series aluminum alloys for use in the products and methods described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199. [0034] Suitable 3xxx series aluminum alloys for use as the second aluminum alloy described herein include, for example, AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065.

[0035] As another example, the second aluminum alloy can be a 6xxx series aluminum alloy. Suitable 6xxx series aluminum alloys for use as the second aluminum alloy described herein include, for example, AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0036] In some aspects, the first aluminum alloy has a first electrical conductivity that is higher than a second electrical conductivity of the second aluminum alloy. For example, the first aluminum alloy can have an electrical conductivity above 50% International Annealed Copper Standard (IACS), such as from 51% IACS to 70% IACS, from 60% IACS to 80% IACS, or from 55% IACS to 90% IACS. In some examples, the electrical conductivity of the first aluminum alloy can be 55% IACS, 60% IACS, 65% IACS, 70% IACS, 75% IACS, 80% IACS, 85% IACS, 90% IACS, 95% IACS, 100% IACS, or anywhere in between.

[0037] The stacked arrangement of the first layer 110 and the second layer 115 can undergo rolling, such as hot rolling or cold rolling, using one or more passes to produce the clad aluminum alloy product 105. The rolling step can cause the first layer 110 to be coupled to the second layer 115, forming the clad aluminum alloy product 105. In some implementations, a combined electrical conductivity of the clad aluminum alloy product 105 can be greater than the second electrical conductivity of the second aluminum alloy by at least 40% (e.g., by 40%, 50%, 60%, 70%, 80%, 90%, 100%, etc.). The clad aluminum alloy product 105 can provide suitable electrical conductivity for battery applications despite incorporating high amounts of recycled content from the second aluminum alloy.

[0038] In some embodiments, the clad aluminum alloy product 105 can be a foil product. For example, the clad aluminum alloy product 105 may have a thickness ranging from 10 microns to 20 microns (e.g., from 10 microns to 15 microns, from 15 microns to 20 microns, etc.). In some implementations, the thickness of the clad aluminum alloy product may be 10 microns, 11 microns, 12 microns, 13 microns, 14 microns, 15 microns, 16 microns, 17 microns, 18 microns, 19 microns, 20 microns, or anywhere in between. In some implementations, the clad aluminum alloy product 105 can be used to produce a cathode current collector that can have an electrical conductivity greater than 40% IACS (e.g., from 45% IACS to 60% IACS or from 50% IACS to 80% IACS). For example, the electrical conductivity of the cathode current collector can be 45% IACS, 50% IACS, 55% IACS, 60% IACS, 65% IACS, 70% IACS, 75% IACS, 80% IACS, 85% IACS, 90% IACS, 95% IACS, 100% IACS, or anywhere in between. The electrical conductivity of the cathode current collector can be suitable to be incorporated in a battery, such as a lithium-ion battery.

Recycled Aluminum Alloy Materials for Clad Aluminum Alloy Products

[0039] The clad aluminum alloy products described herein can tolerate high amounts of recycled aluminum alloy materials and still exhibit desirable electrochemical properties, thereby reducing greenhouse gas emissions associated with producing the clad aluminum alloy products. Examples of recycled aluminum alloy materials can include used beverage can (UBC) scrap, casting scrap, or brazing scrap. The impact of the impurities and/or alloying elements on the electrochemical properties of the clad aluminum alloy products from incorporating the recycled aluminum alloy materials is reduced by coupling the recycled aluminum alloy materials with another aluminum alloy that has high electrical conductivity. The clad aluminum alloy products described herein can include less primary aluminum than conventional aluminum alloys for energy storage applications, thereby lowering carbon emissions during production to reduce an overall carbon footprint. For example, the clad aluminum alloy products described herein may include higher amounts of recycled content compared to conventional Ixxx series aluminum alloys. Aluminum alloy products produced from recycled content with little to no primary aluminum minimize potential environmental impacts.

[0040] In some aspects, the second aluminum alloy of the clad aluminum alloy product can have a higher amount of recycled content compared to the first aluminum alloy. For example, the second aluminum alloy can have a recycled content of at least 50 wt. % (e.g., from 50 wt. % to 70 wt. %, from 60 wt. % to 80 wt. %, or from 70 wt. % to 100 wt. %). The recycled content of the second aluminum alloy can be 50 wt. %, 60 wt. %, 70 wt. %, 80 wt. %, 90 wt. %, 100 wt. %, or anywhere in between.

[0041] In some aspects, the aluminum alloys described herein include less than 50 % primary aluminum (e.g., less than 49 %, less than 48 %, less than 47 %, less than 46 %, less than 45 %, less than 44 %, less than 43 %, less than 42 %, less than 41 %, less than 40 %, less than 39 %, less than 38 %, less than 37 %, less than 36 %, less than 35 %, less than 34 %, less than 33 %, less than 32 %, less than 31 %, less than 30 %, less than 29 %, less than 28 %, less than 27 %, less than 26 %, less than 25 %, less than 24 %, less than 23 %, less than 22 %, less than 21 %, less than 20 %, less than 19 %, less than 18 %, less than 17 %, less than 16 %, less than 15 %, less than 14 %, less than 13 %, less than 12 %, less than 11 %, less than 10 %, or less than 5 % primary aluminum). All are expressed in wt. %.

Methods of Using the Disclosed Clad Aluminum Alloy Products

[0042] The clad aluminum alloy products described herein can be used in battery applications, such as lithium-ion batteries. For example, the disclosed alloy products can be used as current collectors for batteries or electrochemical cells. As a non-limiting example, the clad aluminum alloy products described herein can be provided as a cathode foil (e.g., a cathode current collector) in a lithium-ion battery.

[0043] The clad aluminum alloy products can also be used in electronics applications. For example, the clad aluminum alloy products can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the clad aluminum alloy products can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones), tablet bottom chassis, and other portable electronics.

[0044] The examples disclosed herein will serve to further illustrate aspects of the invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the invention. The examples and embodiments described herein may also make use of conventional procedures, unless otherwise stated. Some of the procedures are described herein for illustrative purposes.

EXAMPLE 1

[0045] FIG. 2 provides a graph of electrical conductivity versus foil thickness for comparative aluminum alloys and an example clad aluminum alloy product. As shown in FIG. 2, a sample clad aluminum alloy product was tested to determine electrical conductivity of the sample clad aluminum alloy product. The sample clad aluminum alloy product was prepared by cold rolling a first aluminum alloy (AA1050) selected from the Ixxx aluminum alloy series and a second aluminum alloy (AA3104) selected from the 3xxx aluminum alloy series. The first aluminum alloy and the second aluminum alloy had a thickness of 300 pm prior to the cold rolling step. Subsequent to cold rolling, the sample clad aluminum alloy product had a thickness of 100 pm.

[0046] Data set 205 corresponds to the electrical conductivity of a first comparative aluminum alloy prepared using the first aluminum alloy. Similarly, data set 210 corresponds to the electrical conductivity of a second comparative aluminum alloy prepared using the second aluminum alloy. As shown, the electrical conductivity of the first comparative aluminum alloy is higher than the second comparative aluminum alloy at each thickness tested.

[0047] Data points 215 and 220 correspond to electrical conductivity of a respective side of the sample clad aluminum alloy product. In particular, data point 215 corresponds to a first side of the sample clad aluminum alloy product associated with the first aluminum alloy. Data point 220 corresponds to a second side of the sample clad aluminum alloy product associated with the second aluminum alloy. As shown, the first side of the sample clad aluminum alloy product had a slightly higher electrical conductivity than the second side. Additionally, as indicated by data points 215 and 220, both sides of the sample clad aluminum alloy product exhibited a higher electrical conductivity than the second comparative aluminum alloy and a lower electrical conductivity than the first comparative aluminum alloy. In other words, cladding the first aluminum alloy with the second aluminum alloy to produce the clad aluminum alloy product can result in an increase in electrical conductivity compared to the second aluminum alloy despite incorporating recycled content from the second aluminum alloy. ILLUSTRATIVE ASPECTS

[0048] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4”).

[0049] Aspect l is a clad aluminum alloy product, comprising: a first layer comprising a first aluminum alloy that has a first electrical conductivity above 50% IACS; and a second layer coupled to the first layer, the second layer comprising a second aluminum alloy including a recycled content of at least 50 wt. %, wherein the clad aluminum alloy product is a foil.

[0050] Aspect 2 is the clad aluminum alloy product of any previous or subsequent aspect, wherein the second aluminum alloy is selected from a different aluminum alloy series than the first aluminum alloy.

[0051] Aspect 3 is the clad aluminum alloy product of any previous or subsequent aspect, wherein the first aluminum alloy is a Ixxx series aluminum alloy.

[0052] Aspect 4 is the clad aluminum alloy product of any previous or subsequent aspect, wherein the second aluminum alloy is a 3xxx series aluminum alloy.

[0053] Aspect 5 is the clad aluminum alloy product of any previous or subsequent aspect, wherein the second aluminum alloy is a 6xxx series aluminum alloy.

[0054] Aspect 6 is the clad aluminum alloy product of any previous or subsequent aspect, wherein a combined electrical conductivity of the clad aluminum alloy product is greater than 40% IACS.

[0055] Aspect 7 is the clad aluminum alloy product of any previous or subsequent aspect, wherein the electrical conductivity of the second aluminum alloy is a second electrical conductivity, and wherein the combined electrical conductivity of the clad aluminum alloy product is greater than the second electrical conductivity of the second aluminum alloy by at least 40%.

[0056] Aspect 8 is the clad aluminum alloy product of any previous or subsequent aspect, wherein the clad aluminum alloy product has a thickness ranging from 10 microns to 20 microns.

[0057] Aspect 9 is a method of producing a clad aluminum alloy product, the method comprising: providing a first aluminum alloy that has an electrical conductivity above 50% IACS and a second aluminum alloy comprising a recycled content of at least 50 wt. %; and processing the first aluminum alloy and the second aluminum alloy to produce the clad aluminum alloy product by coupling the first aluminum alloy to the second aluminum alloy. [0058] Aspect 10 is the method of any previous or subsequent aspect, wherein processing the first aluminum alloy and the second aluminum alloy comprises: providing a stacked arrangement comprising the first aluminum alloy and the second aluminum alloy; and rolling the stacked arrangement to produce the clad aluminum alloy product, wherein the first aluminum alloy forms a first layer coupled to a second layer comprising the second aluminum alloy.

[0059] Aspect 11 is the method of any previous or subsequent aspect or 10, wherein providing the first aluminum alloy and the second aluminum alloy comprises selecting the second aluminum alloy from a different aluminum alloy series than the first aluminum alloy. [0060] Aspect 12 is the method of any previous or subsequent aspect, wherein the first aluminum alloy is a Ixxx series aluminum alloy.

[0061] Aspect 13 is the method of any previous or subsequent aspect, wherein the second aluminum alloy is a 3xxx series aluminum alloy.

[0062] Aspect 14 is the method of any previous or subsequent aspect, wherein the second aluminum alloy is a 6xxx series aluminum alloy.

[0063] Aspect 15 is the method of any previous or subsequent aspect, wherein the clad aluminum alloy product has a thickness ranging from 10 microns to 20 microns.

[0064] Aspect 16 is a battery comprising a cathode current collector produced using the clad aluminum alloy product of any of any previous or subsequent aspect.

[0065] Aspect 17 is the battery of any previous or subsequent aspect, wherein the cathode current collector has an electrical conductivity greater than 40% IACS.

[0066] Aspect 18 is the battery of any previous or subsequent aspect, wherein the battery is a lithium-ion battery.

[0067] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

WHAT IS CLAIMED IS:

1. A clad aluminum alloy product, comprising: a first layer comprising a first aluminum alloy that has a first electrical conductivity above 50% IACS; and a second layer coupled to the first layer, the second layer comprising a second aluminum alloy including a recycled content of at least 50 wt. %, wherein the clad aluminum alloy product is a foil.

2. The clad aluminum alloy product of claim 1, wherein the second aluminum alloy is selected from a different aluminum alloy series than the first aluminum alloy.

3. The clad aluminum alloy product of claim 2, wherein the first aluminum alloy is a Ixxx series aluminum alloy.

4. The clad aluminum alloy product of any one of claims 1-3, wherein the second aluminum alloy is a 3xxx series aluminum alloy.

5. The clad aluminum alloy product of any one of claims 1-3, wherein the second aluminum alloy is a 6xxx series aluminum alloy.

6. The clad aluminum alloy product of any of claims 1-3, wherein a combined electrical conductivity of the clad aluminum alloy product is greater than 40% IACS.

7. The clad aluminum alloy product of claim 6, wherein the electrical conductivity of the second aluminum alloy is a second electrical conductivity, and wherein the combined electrical conductivity of the clad aluminum alloy product is greater than the second electrical conductivity of the second aluminum alloy by at least 40%.

8. The clad aluminum alloy product of claim 1, wherein the clad aluminum alloy product has a thickness ranging from 10 microns to 20 microns.

9. A method of producing a clad aluminum alloy product, the method comprising: providing a first aluminum alloy that has an electrical conductivity above 50% IACS and a second aluminum alloy comprising a recycled content of at least 50 wt. %; and processing the first aluminum alloy and the second aluminum alloy to produce the clad aluminum alloy product by coupling the first aluminum alloy to the second aluminum alloy.

10. The method of claim 9, wherein processing the first aluminum alloy and the second aluminum alloy comprises: providing a stacked arrangement comprising the first aluminum alloy and the second aluminum alloy; and rolling the stacked arrangement to produce the clad aluminum alloy product, wherein the first aluminum alloy forms a first layer coupled to a second layer comprising the second aluminum alloy.

11. The method of claim 9 or 10, wherein providing the first aluminum alloy and the second aluminum alloy comprises selecting the second aluminum alloy from a different aluminum alloy series than the first aluminum alloy.

12. The method of any one of claims 9-11, wherein the first aluminum alloy is a Ixxx series aluminum alloy.

13. The method of any one of claims 9-11, wherein the second aluminum alloy is a 3xxx series aluminum alloy.

14. The method of any one of claims 9-11, wherein the second aluminum alloy is a 6xxx series aluminum alloy.

15. The method of any one of claims 9-13, wherein the clad aluminum alloy product has a thickness ranging from 10 microns to 20 microns.

16. A battery comprising a cathode current collector produced using the clad aluminum alloy product of any of claims 1-7.

17. The battery of claim 16, wherein the cathode current collector has an electrical conductivity greater than 40% IACS.

18. The battery of claim 16 or 17, wherein the battery is a lithium-ion battery.