# US 12,015,146 B2 · Compositions and methods for multilayer dry coated and wet cast film hybrid electrode films

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- Number: US 12,015,146 B2
- Document ID: US12015146B2
- Status: Granted
- Kind: B2
- Application number: 18/358,814
- Filed: 2023-07-25
- Published: 2023-11-23
- Granted: 2024-06-18
- Earliest claimed: 2019-03-29
- Assignees: Tesla, Inc.
- Applicants: Tesla, Inc.
- Inventors: Joon Ho Shin; Hieu Minh Duong; Amado Marcelino Garcia Acevedo
- Web page: https://patentgrep.com/patent/US12015146B2

## CPC

- H01M 4/02: Electrodes composed of, or comprising, active material
- H01M 4/366: {as layered products}
- H01G 11/26: characterised by their structure, e.g. multi-layered, porosity or surface features
- H01G 11/28: arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
- H01G 11/38: Carbon pastes or blends; Binders or additives therein
- H01G 11/86: specially adapted for electrodes (carbonisation or activation of carbon for the manufacture of electrodes H01G11/34)
- H01M 4/621: {Binders}
- H01M 4/8896: {Pressing, rolling, calendering (membrane electrode assemblies H01M8/1004)}
- Y02E 60/10: Energy storage using batteries
- Y02E 60/50: Fuel cells
- Y02T 10/70: Energy storage systems for electromobility, e.g. batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

Provided herein are energy storage device electrode films comprising a hybrid electrode film, and methods of forming such multilayer hybrid electrode films and energy storage devices comprising multilayer hybrid electrode films. Each hybrid electrode film may comprise a self-supporting dry coated active layer and a wet cast active layer, wherein each active layer comprises a binder and an active material. The binder and/or active material may be the same or different as any other active layer. The hybrid multilayer electrode film may further comprise at least one additional layer, and the hybrid multilayer electrode film may be laminated with a current collector to form an electrode.

## Claims

### Claim 1

A multilayer electrode film for use in an energy storage device comprising:
a dry-processed active layer comprising:
a first active material; and
a fibrillized binder;
wherein the dry-processed active layer is self-supporting and absent of processing solvent residue; and
a wet-processed active layer comprising:
a second active material; and
at least some processing solvent residue.

### Claim 2 (depends on 1)

The multilayer electrode film of claim 1, wherein the dry-processed active layer and the wet-processed active layer are directly disposed over each other.

### Claim 3 (depends on 1)

The multilayer electrode film of claim 1, further comprising an additional layer.

### Claim 4 (depends on 3)

The multilayer electrode film of claim 3, wherein the additional layer is disposed over both the dry-processed active layer and the wet-processed active layer.

### Claim 5 (depends on 3)

The multilayer electrode film of claim 3, wherein the additional layer is disposed between the dry-processed active layer and the wet-processed active layer.

### Claim 6 (depends on 3)

The multilayer electrode film of claim 3, wherein the additional layer is a multilayer additional layer.

### Claim 7 (depends on 3)

The multilayer electrode film of claim 3, wherein the additional layer is selected from the group consisting of a composite powder, a composite film, an adhesive paste, a composite powder paste, and combinations thereof.

### Claim 8 (depends on 7)

The multilayer electrode film of claim 7, wherein the composite powder comprises a powder selected from the group consisting of Si, SiOx, LixSiOy alloy, Li, Li alloy, and combinations thereof.

### Claim 9 (depends on 7)

The multilayer electrode film of claim 7, wherein the composite film comprises a powder selected from the group consisting of Si, SiOx, LixSiOy alloy, Li, Li alloy, and combinations thereof.

### Claim 10 (depends on 7)

The multilayer electrode film of claim 7, wherein the adhesive paste comprises an adhesive selected from the group consisting of a room temperature ionic liquid, a conductive carbon paste, a liquid polymer, and combinations thereof.

### Claim 11 (depends on 7)

The multilayer electrode film of claim 7, wherein the composite powder paste further comprises a ceramic filler.

### Claim 12 (depends on 1)

The multilayer electrode film of claim 1, wherein the multilayer electrode film is free-standing.

### Claim 13 (depends on 1)

An electrode comprising a current collector and the multilayer electrode film of claim 1.

### Claim 14 (depends on 13)

A battery comprising the electrode of claim 13.

### Claim 15

A multilayer electrode film fabrication process comprising:
disposing a dry-processed active layer over a wet-processed active layer; and
laminating the dry-processed and wet-processed active layers to form a multilayer electrode film,
wherein the dry-processed active layer comprises a first active material and a fibrillized binder, and the dry-processed active layer is absent of processing solvent residue, and
wherein the wet-processed active layer comprises a second active material and at least some processing solvent residue.

### Claim 16 (depends on 15)

The process of claim 15, wherein laminating is performed by a process selected from the group consisting of passing the dry-processed and wet-processed active layers between two rollers, passing the dry-processed and wet-processed active layers through one roller while positioned on a moving station, pressing the dry-processed and wet-processed active layers between two plates, and combinations thereof.

### Claim 17 (depends on 15)

The process of claim 15, wherein the dry-processed active layer is a rolled free-standing film before being disposed on the wet-processed active layer, and wherein disposing the dry-processed active layer on the wet-processed active layer comprises unrolling the dry-processed active layer.

### Claim 18 (depends on 15)

The process of claim 15, further comprising disposing an additional layer over the wet-processed active layer.

### Claim 19 (depends on 15)

The process of claim 15, further comprising disposing an additional layer over the dry-processed active layer.

### Claim 20 (depends on 15)

The process of claim 15, further comprising disposing an additional layer over the multilayer electrode film.

### Claim 21

A multilayer electrode film fabrication process comprising:
disposing an active layer slurry mixture over a dry-processed active layer;
drying the disposed active layer slurry mixture to form a wet-processed active layer comprising:
a second active material; and
at least some processing solvent residue; and
laminating the dry-processed and wet-processed active layers to form a multilayer electrode film,
wherein the dry-processed active layer comprises a first active material and a fibrillized binder, and the dry-processed active layer is absent of processing solvent residue, and
wherein the active layer slurry mixture comprises the second active material and a processing solvent.