Bendable, creasable, and printable batteries with enhanced safety and high temperture stability - methods of fabrication, and methods of using the same

Abstract

A composite electrode. The composite electrode including an active material, a conductive additive, a binder, and a solvent. The composite electrode may be cast or printed.

What is claimed is: 
     
         1 . A printable or castable composition for electrode fabrication, the composition comprising:
 solids comprising an active material selected from the group consisting of Li 4 Ti 5 O 12 , LiCoO 2 , LiMn 2 O 4 , LiFePO 4 , LiNiMnCoO 2 , carbon nanofibers, silicon, graphite, and combinations thereof;   a conductive additive comprising a carbon based material or a metallic material; and a binder;   a solvent; and   optionally, a non-solvent having a boiling point that is greater than a boiling point of the solvent, is configured to cause binder self-interaction inducing porosity,   wherein an amount of the active material of the solids ranges from 25 wt % to 80 wt % of the suspension, an amount of the conductive additive of the solids ranges from 10 wt % to 40 wt % of the suspension, and an amount of the binder of the solids ranges from 10 wt % to 50 wt % of the suspension,   wherein a weight fraction of non-solvent to solvent ranges from 0 wt % to 30 wt %, and   wherein a viscosity of the composition is selected for printing or casting.   
     
     
         2 . The composition of  claim 1 , wherein the conductive additive is selected from the group consisting of graphite, carbon black, carbon nanotubes, carbon nanofibers, Al, Cu, Ag, Ni, and combinations thereof. 
     
     
         3 . The composition of  claim 1 , wherein the binder is selected from the group consisting of polyvinylidene fluoride (PVDF), polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP), polytetrafluoroethylene (PTFE), polyethylene oxide (PEO), poly(methyl methacrylate) (PMMA), polyacrylonitrile (PAN), and combinations thereof. 
     
     
         4 . The composition of  claim 1 , wherein the solvent is selected from the group consisting of N-methyl-2-pyrrolidone (NMP), dimethylformamide (DMF), acetone, dimethyalcetamide (DMAc), dimethyl sulfoxide (DMSO), trimethyl urea, triethyl phosphate, and combinations thereof. 
     
     
         5 . The composition of  claim 1 , wherein the non-solvent is selected from the group consisting of non-solvent is selected from the group consisting of glycerol, water, ethanol, methanol, ethylene glycol, diethylene glycol, triethylene glycol, hexane, heptane, and combinations thereof. 
     
     
         6 . A method of fabricating a composite electrode, the method comprising:
 preparing the composition of  claim 1  as a suspension;   casting or printing the suspension; and   drying the suspension.   
     
     
         7 . The method of  claim 6 , wherein the conductive additive is selected from the group consisting of graphite, carbon black, carbon nanotubes, carbon nanofibers, Al, Cu, Ag, Ni, and combinations thereof. 
     
     
         8 . The composition of  claim 6 , wherein the binder is selected from the group consisting of polyvinylidene fluoride (PVDF), polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP), polytetrafluoroethylene (PTFE), polyethylene oxide (PEO), poly(methyl methacrylate) (PMMA), polyacrylonitrile (PAN), and combinations thereof. 
     
     
         9 . The composition of  claim 6 , wherein the solvent is selected from the group consisting of N-methyl-2-pyrrolidone (NMP), dimethylformamide (DMF), acetone, dimethyalcetamide (DMAc), dimethyl sulfoxide (DMSO), trimethyl urea, triethyl phosphate, and combinations thereof. 
     
     
         10 . The method of  claim 6 , wherein the non-solvent is selected from the group consisting of glycerol, water, ethanol, methanol, ethylene glycol, diethylene glycol, triethylene glycol, hexane, heptane, and combinations thereof. 
     
     
         11 . A composite cathode prepared in accordance with the method of  claim 6 , wherein the active material is LiFePO 4 . 
     
     
         12 . A composite anode prepared in accordance with the method of  claim 6 , wherein the active material is Li 4 Ti 5 O 12 . 
     
     
         13 . A battery comprising:
 a cathode comprising the printed or cast and dried composition of  claim 1 , wherein the active material is LiFePO 4 ;   an anode;   a separator positioned between the cathode and the anode; and   an electrolyte,   with the proviso that no current collector is within the battery.   
     
     
         14 . The battery of  claim 13 , wherein the anode comprises the printed or cast and dried composition of  claim 1  and the active material being Li 4 Ti 5 O 12 . 
     
     
         15 . The battery of  claim 13 , further comprising:
 an encapsulator configured to surround the cathode, the anode, the separator, and the electrolyte.   
     
     
         16 . The battery of  claim 13 , wherein the electrolyte is LiPF 6  in a carbonate. 
     
     
         17 . The battery of  claim 16 , wherein the carbonate is selected from the group consisting of ethylene carbonate (EC), diethyl carbonate (DEC), dimethyl carbonate (DMC), ethyl methyl carbonate (EMC), propylene carbonate (PC), and combinations thereof.