Abstract:
An electrode has a first set of stripes of a graphite-containing material, and a second set of stripes of silicon-containing material interdigitated with the first set of stripes. A method of manufacturing an electrode includes extruding first and second materials simultaneously onto a substrate in interdigitated stripes, wherein the first material comprises a graphite-containing material and the second material comprises a silicon-containing material.

Description:
RELATED APPLICATIONS 
       [0001]    This application is related to the following applications, all of which are incorporated by reference herein in their entity: 
         [0002]    U.S. patent Ser. No. 13/727,960, “Advanced, High Power and Energy Battery Electrode Manufactured by Co-Extrusion Printing,” filed Dec. 27, 2012; 
         [0003]    U.S. patent Ser. No. 13/727,993, “Three-Dimensional Co-Extruded Battery Electrodes,” filed Dec. 27, 2012; 
         [0004]    U.S. patent Ser. No. 14/034,855, “Dispersant for Improved Battery Electrode Formulations,” filed Sep. 24, 2013; 
         [0005]    U.S. patent Ser. No. 14/448,590, “High Energy and Power Li-ion Battery Having Less Stress and Long-Term Cycling Capacity,” filed Jul. 31, 2014; 
         [0006]    U.S. patent Ser. No. 14/329,537, “High Performance All Solid Lithium Sulfur Battery with Fast Lithium Ion Conduction,” filed Jul. 11, 2014; and 
         [0007]    U.S. patent Ser. No. 14/511,910, “Trapping Dissolved Polysulfide for High Performance Batteries,” filed Oct. 10, 2014. 
     
    
     BACKGROUND 
       [0008]    A strong demand exists for lithium ion (Li-ion) batteries with high energy density, longer cycle life, and better safety in portable electronic devices and power supply application such a long-range drivable electric vehicles (EVs) and hybrid EVs. Even though tremendous advances have occurred in Li-ion batteries, most still use commercial graphite as the main anode material for the last twenty years. Due to low electrochemical capacity of graphite (372 mAh/g), substantial efforts have focused on developing new negative electrode materials with improved storage capacity, especially silicon (Si) as a strong candidate because it has the highest theoretical capacity (Li 4.4 Si≈4200 mAh/g) of all know materials, and being abundant and inexpensive. Generally, it shows a higher voltage plateau than that of graphite and lithiated silicon is more stable in typical electrolytes than lithiated graphite, making lithiated silicon safer. 
         [0009]    However, commercialization of silicon has many difficulties because poor cycling performance resulting from large volume changes (˜300%) upon the intercalation of Li-ion during charge step compared to that (˜10%) of graphic. Current research efforts have mostly focused on the improvement of silicon anode cycling performance using several approaches such as silicon-carbon (Si—C) composite with reducing the Si particle size, adding the Si particles in a carbon matrix, creating a carbon coating layer on Si particles, applying different binders with higher bonding strength, or restricting severe volume changes of Si using a three-dimension copper framework. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  shows a graph of changes in the charge/discharge capacity of silicon-based anode electrodes as a function of the number of cycles for micrometer-sized silicon particles. 
           [0011]      FIG. 2  shows a graph of changes in the charge/discharge capacity of silicon-based anode electrodes as a function of the number of cycles for nanometer-sized silicon particles. 
           [0012]      FIG. 3  shows a graph of changes in the charge/discharge capacity of silicon-based anode electrodes as a function of the number of cycles for micrometer-sized silicon particles in a carbon matrix. 
           [0013]      FIG. 4  shows a graph of changes in the charge/discharge capacity of silicon-based anode electrodes as a function of the number of cycles for nanometer-sized silicon particles in a carbon matrix. 
           [0014]      FIG. 5  shows a representation of a carbon-coated silicon particle in a carbon composite. 
           [0015]      FIG. 6  shows a graph of changes in the charge/discharge capacity of silicon-based anode electrodes as a function of the number of cycles for carbon-coated particles in a carbon composite. 
           [0016]      FIG. 7  shows a schematic diagram representing broken electric connections for a conventional binder system and interconnected electronic connections for new binder system. 
           [0017]      FIG. 8  shows a graph of specific capacity versus a number of cycles for different binder systems. 
           [0018]      FIG. 9  shows a graph of specific capacity versus a number of cycles for a Si/PFFOMB composite. 
           [0019]      FIG. 10  shows a representation of an image of a three-dimensional copper cellular architecture. 
           [0020]      FIG. 11  shows a top view of the copper cellular architecture with infiltrated silicon powders. 
           [0021]      FIGS. 12 and 13  show cycle performance of silicon anode electrodes with and without three-dimensional copper based cellular framework. 
           [0022]      FIG. 14  shows a graph of specific capacity versus the fraction of silicon in the anode electrode. 
           [0023]      FIG. 15  shows an embodiment of a conventional silicon-graphite anode. 
           [0024]      FIG. 16  shows an embodiment of a silicon graphite anode comprising alternating, interdigitated stripes of materials. 
           [0025]      FIG. 17  shows another embodiment of a silicon graphite anode. 
           [0026]      FIG. 18  shows an embodiment of a silicon graphite anode comprising alternating, interdigitated stripes of materials having an oxide coating. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0027]    In order to improve the specific capacity of negative silicon-based electrodes, approaches reducing the silicon particles to nanometer size, adding the silicon particles into carbon matrix composite, and creating carbon coating layer on silicon particles, have been explored.  FIGS. 1 and 2  show the cycling behaviors of the micrometer and nanometer-sized Si anode electrodes. Even though the discharge capacity of nanometer-sized silicon at the first discharge is higher than that of micrometer-sized silicon, both cells have experienced severe capacity fade after 15 cycles and cell capacities drop to almost zero. Nanometer silicon particles were expected to reduce or avoid the mechanical stress developed by large volume expansion of Li—Si alloys, but the reduction of silicon particle size is not the critical parameter required for long battery cycle life. 
         [0028]      FIGS. 3 and 4  represent the cycling performances of the Si—C composite anodes containing micrometer or nanometer-sized silicon particles, respectively. Compared to silicon anode electrodes in  FIGS. 1 and 2 , Si—C composites demonstrate much lower irreversible capacity at the first cycle, higher electrochemical lithiation of silicon, and better capacity retention with cycling.  FIG. 5  shows the image of a silicon nanoparticle  10  coated with a layer of silicon oxide  12  and a layer of carbon represented by the black arrows.  FIG. 6  shows a graph of the performance versus cycle number of a silicon-based anode electrode, respectively.  FIG. 7  shows a schematic diagram of a traditional binder system  22  that lacks the mechanical integrity of the silicon-based anode electrode and lost electronic connectivity during many cycling steps. Because of the larger breakage elongation of the SBR (styrene butadiene rubber) elastomeric binder, the process used SBR (styrene butadiene rubber) and CMC (sodium carboxymethyl cellulose) to increase the elasticity of the binder material to the cycling stability of the Si-based anode electrode, and replaced standard PVDF (polyvinylidene fluoride). 
         [0029]    Using an SBR and CMC binder mixture induces low irreversible capacity loss in the first cycle and low capacity losses upon the cycling, but generally does not retain a good electrochemical cycling performance similar to silicon-based anode electrodes. In order to maintain the electrical and mechanical integrity, a new conductive polymer binder  22  on the right side of  FIG. 7  was developed by modifying the energy levels of the polymer conduction state, that is, the lowest unoccupied molecular orbital (LUMO). In the LUMO the electrons could cathodically dope the polymer to achieve proper electronic conductivity. Starting with the polyfluorene type polymers (PFFO), two functional groups of carbonyl and methylbenzoic (MB) ester were introduced, creating PFFOMB. The electrodes based on PAN (polyacrylonitrile) or PVDF (poly vinylidene fluoride), shown in  FIG. 8  as curves  30  and  32 , respectively, demonstrated poor performance due to the insulating nature of the polymer matrix. On the other hand, using a new binder system of PFFOMB shown as  34  in  FIG. 8 , creates high specific capacity and stable cycling performance with 2100 mAh/g for Si after 650 cycles as show in  FIG. 9 . 
         [0030]    As another approach to restrict severe volume changes of silicon anode electrodes used a copper scaffold with 3D cellular architecture.  FIGS. 10 and 11  show the images of a Si anode electrode before and after casting silicon powders into a 3D copper framework. In  FIG. 10 , the copper scaffold  50  has openings such as  52 . In  FIG. 11 , a silicon particular  54  has filled the opening  52 .  FIGS. 12 and 13  show the result of a cycling test for silicon anode electrodes prepared with or without 3D cellular framework, respectively. 
         [0031]    Both anode electrodes characterized in  FIGS. 12 and 13  were prepared by casting slurries of 72 wt % Si, 20 wt % carbon black and 8 wt % poly (vinylidene fluoride) (PVDF) dissolved in N-methylpyrrolidinone (NMP). In spite of the large amount of carbon black as an electric conductive additive, coulombic efficiency of the anode electrode without the 3D cellular framework, shown in  FIG. 13 , starts to fall rapidly only after 26 cycles, which is associated with loose electrode structure due to enormous volume changes. However, the 3D scaffold-based Si anode electrodes demonstrated much better coulombic efficiency (above 90%) and improved performance with a completion of 63 charge-discharge cycles. The 3D matrix offers such a good conductive environment that the active materials can be stuck to the current collector without addition of conductive agents. With the ductility of a metal framework, it can also relieve the stress due to the volume changes, preventing mechanical failure of electrodes. 
         [0032]    Given the reduction of Si particle size, adding the Si particles in a carbon matrix, creating carbon coating layer on Si particles, and capturing volume change of Si using the 3D copper framework as explained above, relieving the stress due to the volume change of Si particle during alloying and de-alloying becomes critical to improve cyclability and columbic efficiency of Si based anode electrodes. While microstructure modification of anode electrodes such as applying a 3D copper framework works well to relieve internal stress, it reduces the cell&#39;s energy density since the total mass of the inactive copper framework needs to be added so that it is not a commercially viable option. Here, the embodiments propose commercially viable Si based anode electrodes to effectively dissipate internal stress, maintain high electronic conductivity and longer cycling performance, and delivery much higher volumetric energy density. 
         [0033]      FIG. 14  shows the resulting enhancements of specific capacities due to the addition of silicon into a graphite anode as curve  60 . Specific capacity increased to 1161 mAh/g or 1950 mAh/g with the addition of silicon of 20 or 40 weight percent, respectively. One should note that the weight percent of silicon may be up to 50 weight percent. Therefore, if one can control large volume change of silicon, it will be easy to produce high density anode electrode without developing new materials. 
         [0034]    However, in a conventional, simple mixing process, control of the location of silicon  70  in the graphite matrix comprised of graphite particles such as  72  becomes difficult as shown in  FIG. 15 . Even though the specific capacity of the anode electrode increases as addition of silicon material, the cycle performance will suffer by non-homogenously dispersed silicon particles, especially when the silicon particles are mostly located near the current collector. Silicon will experience large volume changes and detach from the current collector so that high contact resistance will degrade cycling performance of silicon-based anodes. 
         [0035]    Embodiments here reduce large volume changes of the silicon and increase the specific capacity and volumetric energy density of Li-ion battery when silicon material is added into a graphite anode.  FIG. 16  shows a new anode electrode with duplex structures consisting of alternating, or interdigitated, stripes of two materials, one graphite  80  and the other silicon or the mixture of silicon and graphite  82 . Compared to the simple mixed structure in the conventional anode electrode, the duplex structure provides a unique benefit of easily adjusting the portion of the duplex structure according to the overall volume change of silicon material. 
         [0036]    As explained earlier, graphite has experienced much less volume change (˜10%) compared to the silicon (˜300%) during charging and discharging steps. Therefore, graphite matrixes in the duplex structures not only alleviate the volume change of silicon, but also provides electric interconnection in the electrode. This allows improved cycling stability of Si—C composite. 
         [0037]      FIG. 17  shows an alternative embodiment of the duplex structure. In this structure, as shown in by region  86 , the graphite is first deposited to cover the entire current collector, prior to the addition of the silicon. The use of a co-extrusion print head allows this structure to be manufactured in one printing pass through the control of the materials in the extrusion process. This results in the structure shown in  FIG. 17 . 
         [0038]    In another embodiment, surface modification of Si—C composite with duplex structures on the back-end of the process may include a process of molecular layer deposition (MLD) as shown in  FIG. 18  The MLD process develops an oxide coating layer  90  on the silicon and graphite particles, which help reduce the effect of parasitic side reactions between the liquid electrolyte and electrode surface used in most batteries. It also provides a mechanically robust, flexible coating layer to preserve structure integrity of Si—C composite. 
         [0039]    While conventional processing methods are only able to create the simple structure shown in  FIG. 15 , co-extrusion printing systems reliably produce duplex structures with alternating stripes of two materials, one graphite and the other silicon or the mixture of silicon and graphite. The co-extrusion system feeds multiple viscous, particle-filled pastes into a print head that allows flows of separate fluids to alternately converge into interdigitated stripes of different materials. In the embodiments here, one paste would include graphite particles and another silicon particles or silicon and graphite particles. Similar micro co-extrusion/dispensing systems and methods are discussed in U.S. Pat. No. 7,765,949; U.S. Pat. No. 7,780,812; and U.S. Pat. No. 7,922,471; incorporated by reference here in their entirety, among others. 
         [0040]    In this manner, a negative electrode (anode) results from this process that has high specific capacity over a higher number of cycles, reduced volume change and overall better performance than previous anodes. 
         [0041]    It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the embodiments here.