Continuous production of binder and collector-less self-standing electrodes for li-ion batteries by using carbon nanotubes as an additive

Abstract

The present disclosure is directed to a method and apparatus for continuous production of composites of carbon nanotubes and electrode active material from decoupled sources. Composites thusly produced may be used as self-standing electrodes without binder or collector. Moreover, the method of the present disclosure may allow more cost-efficient production while simultaneously affording control over nanotube loading and composite thickness.

What is claimed is: 
     
         1 . A method of making a self-standing electrode, the method comprising:
 fluidizing an electrode active material; and   co-depositing the fluidized electrode active material and single-walled carbon nanotubes onto a movable porous flexible substrate to form a self-standing electrode that is a composite of the electrode active material and the single-walled carbon nanotubes.   
     
     
         2 . The method of  claim 1 , further comprising synthesizing the single-walled carbon nanotubes in a carbon nanotube synthesis reactor. 
     
     
         3 . The method of  claim 1 , wherein the electrode active material is selected from graphite, hard carbon, lithium metal oxides, lithium iron phosphate, and metal oxides. 
     
     
         4 . The method of  claim 1 , wherein the carbon nanotubes and the electrode active material do not contact each other until they are co-deposited onto the substrate. 
     
     
         5 . The method of  claim 1 , wherein the fluidizing of the electrode active material comprises distributing a carrier gas through, sequentially, a porous frit and a bed of the electrode active material, in an active material container, to form an aerosolized electrode active material. 
     
     
         6 . An apparatus for producing a self-standing electrode, the apparatus comprising:
 a carbon nanotube synthesis reactor configured to synthesize carbon nanotubes;   an active material container configured to fluidize an electrode active material; and   a movable porous flexible substrate configured to collect the carbon nanotubes and the fluidized electrode active material and form the self-standing electrode comprising a composite of the carbon nanotubes and the electrode active material.   
     
     
         7 . The apparatus of  claim 6 , wherein the active material container comprises:
 a porous frit; and   a vertical shaker.   
     
     
         8 . The apparatus of  claim 6 , wherein the movable porous flexible substrate is connected to a roll-to-roll system. 
     
     
         9 . The apparatus of  claim 6 , wherein the electrode active material is selected from graphite, hard carbon, lithium metal oxides, lithium iron phosphate, and metal oxides.