Battery electrode and method of making the same

A process for manufacturing an electrode [electrode (E1)] for an electrochemical cell, said process comprising the following steps:

• step I) combining a polytetrafluoroethylene (PTFE) and a polymer (P) that comprises:
• (A) recurring units derived from at least one α,β-ethylenically unsaturated carboxylic acid monomer [monomer (AA)];
• and
• (B) recurring units derived from at least one (meth)acrylamide monomer [monomer (AM)] of formula (I):
• wherein:
• R5 represents a hydrogen atom or a methyl group, R6 and R7, being the same or different from each other, are selected from the group of a hydrogen atom and a linear or a branched alkyl group having 1 to 6 carbon atoms, R8 and R9, being the same or different from each other, are selected from the group consisting of a hydrogen atom, a linear or a branched alkyl group having 1 to 6 carbon atoms, a carboxylic group and an amide group;
• (C) optionally, recurring units derived from at least one monomer (M) selected from the group consisting of a monomer (M1) and a monomer (M2), wherein:
• the monomer (M1) is an ethylenically unsaturated monomer carrying an unsaturated heterocyclic group having at least one nitrogen atom, said monomer (M1) having the formula (II) below:
• wherein:
• R1 is H or an alkyl group;
• R2 is H or an alkyl group;
• R3 and R4, being the same or different from each other, are selected from the group of a hydrogen atom and a linear or a branched alkyl group having 1 to 6 carbon atoms;
• A is a linkage selected from the group consisting of:
• a single covalent bond;
• and
• a spacer;
• wherein X, Y and Z, independently from each other, are selected from a carbon atom or a nitrogen atom;
• wherein a, b and c are, independently from each other, selected from the integer 1 to 2;
• wherein each dashed-dotted line represents an optional double bond;
• the monomer (M2), different from the monomer (AA) and from the monomer (AM), said monomer (M2) having the formula (II) below:
• wherein:
• Ri is selected from the group consisting of H, —COOH, —CH2COOH and an alkyl group;
• Rii and Riii, being the same or different from each other, are selected from the group of a hydrogen atom, a linear or a branched alkyl group having 1 to 6 carbon atoms, and a —COOH group;
• B is a linkage selected from the group consisting of a —C(O)—O— group and a —C(O)—NH— group;
• Rx is selected from the group of a hydrogen atom and a linear or a branched C3-C20 hydrocarbon chain moiety comprising at least one functional group selected from the group consisting of ether (—O—), heterocyclic group, sulfonic acid group (—SO3H), salt of sulfonic acid group (—SO3Cat), phosphonic acid group (—PO3H2), salt of phosphonic acid group (—PO3Cat2), phosphoric acid group (—OPO3H2), and salt of a phosphoric acid group (—OPO3Cat2), with Cat being a monovalent cation;
• to provide a binder (B);
• step II) dry mixing the at least one electrode active material (AM), the binder (B) and optionally, at least one conductive agent in the absence of a solvent to provide a dry electrode forming composition [composition (C1)];
• step III) feeding the composition (C1) obtained in step ii) to a compactor to form a self-supporting dry film;
• and
• step IV) applying the dry film to an electrically conductive substrate to form the electrode.

A process for manufacturing an electrode for solid-state batteries [electrode (ESS)], said process comprising the following steps:

• a) providing a polymer (P) that comprises:
• (A) recurring units derived from at least one α,β-ethylenically unsaturated carboxylic acid monomer [monomer (AA)];
• and
• (B) recurring units derived from at least one (meth)acrylamide monomer [monomer (AM)] of formula (I):
• wherein:
• R5 represents a hydrogen atom or a methyl group, R6 and R7, being the same or different from each other, are selected from the group of a hydrogen atom and a linear or a branched alkyl group having 1 to 6 carbon atoms, R8 and R9, being the same or different from each other, are selected from the group consisting of a hydrogen atom, a linear or a branched alkyl group having 1 to 6 carbon atoms, a carboxylic group and an amide group;
• (C) optionally, recurring units derived from at least one monomer (M) selected from the group consisting of a monomer (M1) and a monomer (M2), wherein:
• the monomer (M1) is an ethylenically unsaturated monomer carrying an unsaturated heterocyclic group having at least one nitrogen atom, said monomer (M1) having the formula (II) below:
• wherein:
• R1 is H or an alkyl group;
• R2 is H or an alkyl group;
• R3 and R4, being the same or different from each other, are selected from the group of a hydrogen atom, and a linear or a branched alkyl group having 1 to 6 carbon atoms;
• A is a linkage selected from the group consisting of:
• a single covalent bond;
• and
• a spacer;
• wherein X, Y and Z, independently from each other, are selected from a carbon atom or a nitrogen atom;
• wherein a, b and c are, independently from each other, selected from the integer 1 to 2;
• wherein each dashed-dotted line represents an optional double bond;
• the monomer (M2), different from the monomer (AA) and from the monomer (AM), said monomer (M2) having the formula (III) below:
• wherein:
• Ri is selected from the group consisting of H, —COOH, —CH2COOH and an alkyl group;
• Rii and Riii, being the same or different from each other, are selected from the group of a hydrogen atom, a linear or a branched alkyl group having 1 to 6 carbon atoms, and a —COOH group;
• B is a linkage selected from the group consisting of a —C(O)—O— group and a —C(O)—NH— group;
• Rx is selected from the group of a hydrogen atom er and a linear or branched C3-C20 hydrocarbon chain moiety comprising at least one functional group selected from the group consisting of ether (—O—), heterocyclic group, sulfonic acid group (—SO3H), salt of sulfonic acid group (—SO3Cat), phosphonic acid group (—PO3H2), salt of phosphonic acid group (—PO3Cat2), phosphoric acid group (—OPO3H2), and salt of a phosphoric acid group (—OPO3Cat2), with Cat being a monovalent cation;
• b) dry mixing at least one electrode active material (AM), the polymer (P) provided in step i), at least one sulfide-based solid electrolyte or at least one garnet-type inorganic particle based solid electrolyte and, optionally, at least one conductive agent in the absence of a solvent to provide a dry electrode forming composition [composition (C′)];
• c) feeding the composition (C′) obtained in step b) to a compactor to form a self-supporting dry film;
• and
• d) applying the dry film to an electrically conductive substrate to form the electrode.