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

Abstract

A method of applying a separator ink onto a dried electrode of a lithium ion battery. The method includes preparing a separator ink suspension, applying the separator ink suspension onto the dried electrode, and drying the applied separator ink suspension. The separator ink suspension includes a binder comprising 20 wt % to 50 wt % of a total weight of the separator ink suspension, the binder being selected from the group consisting of PVDF, PVDF-HFP, PTFE, PEO, PMMA, PAN, CNC, SBR, and combinations thereof; a solvent selected from the group consisting of NMP, DMF, acetone, DMAc, DMSO, trimethyl urea, triethyl phosphate, and combinations thereof; a non-solvent selected from the group consisting of glycerol, water, ethanol, methanol, ethylene glycol, diethylene glycol, triethylene glycol, hexane, heptane, and combinations thereof; and a ceramic filler comprising 50 wt % to 80 wt % of the total weight of the composite electrolyte the ceramic filler being selected from the group consisting of Al2O3, SiO2, TiO2, MgO, Li2O, LiAlO2, BaTiO3, LAGP, LATP, LLTO, and combinations thereof.

What is claimed is: 
     
         1 . A method of applying a separator ink onto a dried electrode of a lithium ion battery, the method comprising:
 preparing a separator ink suspension comprising: a binder comprising 20 wt % to 50 wt % of a total weight of the separator ink suspension, the binder being selected from the group consisting of PVDF, PVDF-HFP, PTFE, PEO, PMMA, PAN, CNC, SBR, and combinations thereof;   a solvent selected from the group consisting of NMP, DMF, acetone, DMAc, DMSO, trimethyl urea, triethyl phosphate, and combinations thereof;   a non-solvent selected from the group consisting of glycerol, water, ethanol, methanol, ethylene glycol, diethylene glycol, triethylene glycol, hexane, heptane, and combinations thereof; and   a ceramic filler comprising 50 wt % to 80 wt % of the total weight of the composite electrolyte the ceramic filler being selected from the group consisting of Al 2 O 3 , SiO 2 , TiO 2 , MgO, Li 2 O, LiAlO 2 , BaTiO3, LAGP, LATP, LLTO, and combinations thereof;   applying the separator ink suspension onto the dried electrode; and   drying the applied separator ink suspension.   
     
     
         2 . The method of  claim 1 , wherein the dried electrode is uncalendared. 
     
     
         3 . The method of  claim 2 , wherein the separator ink coated dried electrode is calendared. 
     
     
         4 . The method of  claim 1 , wherein the dried electrode is calendared. 
     
     
         5 . The method of  claim 4 , wherein the separator ink coated dried electrode is calendared. 
     
     
         6 . The method of  claim 1 , wherein the dried electrode includes a metal foil current collector. 
     
     
         7 . The method of  claim 1 , wherein the dried electrode is a composite electrode fabricated by a method comprising:
 preparing the composition as a suspension, the suspension 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,   casting, printing, slot die, or doctor blading the suspension; and   drying the suspension   
     
     
         8 . The method of  claim 7 , wherein applying the separator ink includes ink jet printing.