# US 2017/0256367 A1 · Compositions and methods for energy storage device electrodes

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- Number: US 2017/0256367 A1
- Document ID: US20170256367A1
- Status: Published application
- Kind: A1
- Application number: 15/443,939
- Filed: 2017-02-27
- Published: 2017-09-07
- Earliest claimed: 2016-03-01
- Assignees: Maxwell Technologies, Inc.
- Applicants: Maxwell Technologies, Inc.
- Inventors: Santhanam RAMAN; James BORKENHAGEN; Xiaomei XI; Xiang-Rong YE
- Web page: https://patentgrep.com/patent/US20170256367A1

## CPC

- H01G 11/42: Powders or particles, e.g. composition thereof
- H01G 11/06: with one of the electrodes allowing ions to be reversibly doped thereinto, e.g. lithium ion capacitors [LIC]
- 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 11/50: specially adapted for lithium-ion capacitors, e.g. for lithium-doping or for intercalation
- H01G 11/52: Separators
- H01G 11/86: specially adapted for electrodes (carbonisation or activation of carbon for the manufacture of electrodes H01G11/34)
- H01M 4/0416: {involving impregnation with a solution, dispersion, paste or dry powder (H01M4/0438 takes precedence)}
- H01M 4/043: {involving compressing or compaction}
- H01M 4/133: Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
- H01M 4/587: for inserting or intercalating light metals
- H01M 4/621: {Binders}
- H01M 4/625: {Carbon or graphite}
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- Y02E 60/10: Energy storage using batteries
- Y02E 60/13: Energy storage using capacitors
- 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)
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

An energy storage device can include a cathode, an anode, and a separator between the cathode and the anode, where the anode and/or electrode includes an electrode film having a super-fibrillized binder material and carbon. The electrode film can have a reduced quantity of the binder material while maintaining desired mechanical and/or electrical properties. A process for fabricating the electrode film may include a fibrillization process using reduced speed and/or increased process pressure such that fibrillization of the binder material can be increased. The electrode film may include an electrical conductivity promoting additive to facilitate decreased equivalent series resistance performance. Increasing fibrillization of the binder material may facilitate formation of thinner electrode films, such as dry electrode films.

## Claims

### Claim 1

An electrode for use in an energy storage device comprising:
a free-standing dry electrode film, comprising
dry carbon particles; and
dry super-fibrillized binder particles; and
a current collector.

### Claim 2 (depends on 1)

The electrode of claim 1, wherein the dry electrode film has a thickness of about 50 μm to about 120 μm.

### Claim 3 (depends on 1)

The electrode of claim 1, wherein the electrode is an anode.

### Claim 4 (depends on 1)

The electrode of claim 1, wherein the free-standing dry electrode film further comprises a conductive carbon.

### Claim 5 (depends on 1)

The electrode of claim 1, wherein the electrode film comprises the conductive carbon in about 1% to about 5% by mass.

### Claim 6 (depends on 1)

The electrode of claim 1, wherein the electrode is in ionic contact with an electrolyte comprising a lithium salt.

### Claim 7 (depends on 5)

The electrode of claim 5, wherein the electrolyte is further in ionic contact with a cathode.

### Claim 8 (depends on 1)

The electrode of claim 1, wherein the dry super-fibrillized binder particles comprise about 5 wt % to about 7 wt % of the free-standing dry electrode film.

### Claim 9 (depends on 1)

A lithium ion capacitor comprising the electrode of claim 1.

### Claim 10

A method for fabricating a dry energy storage device electrode film comprising:
forming a first dry electrode mixture comprising dry carbon particles and dry fibrillizable binder particles;
super-fibrillizing the binder in the dry electrode film mixture to form a super-fibrillized matrix within the electrode film mixture; and
calendaring the super-fibrillized electrode film mixture to form a free-standing super-fibrillized electrode film.

### Claim 11 (depends on 10)

The method of claim 10, wherein the method is a dry method in which substantially no processing additives are used.

### Claim 12 (depends on 10)

The method of claim 10, further comprising contacting the free-standing electrode film with a current collector to form a first electrode.

### Claim 13 (depends on 12)

The method of claim 12, further comprising forming a second electrode, and inserting a separator between the first electrode and the second electrode.

### Claim 14 (depends on 12)

The method of claim 12, wherein the first electrode is an anode.

### Claim 15 (depends on 10)

The method of claim 10, wherein calendering comprises compressing the free-standing dry electrode film to a thickness of about 50 μm to about 120 μm.

### Claim 16 (depends on 15)

The method of claim 15, wherein calendering to the thickness of about 50 μm to about 120 μm comprises a single calendering step.

### Claim 17 (depends on 10)

The method of claim 10, wherein the dry super-fibrillized binder particles comprise about 5 wt % to about 7 wt % of the super-fibrillized matrix.

### Claim 18 (depends on 10)

The method of claim 10, wherein forming the first mixture further comprises adding conductive carbon particles to the first mixture.

### Claim 19 (depends on 18)

The method of claim 18, wherein the first mixture comprises the conductive carbon particles in about 1% to about 5% by mass.

### Claim 20 (depends on 10)

The method of claim 10, wherein super-fibrillizing the binder comprises:
fibrillizing the binder in the dry electrode film mixture to form a first fibrillized matrix;
destructuring the first fibrillized matrix to form a powdered mixture of carbon particles and fibrillized binder particles; and
fibrillizing the powdered mixture to form a second fibrillized matrix, wherein the second fibrillized matrix comprises the super-fibrillized matrix.