Porous electrodes for electrochemical devices

Abstract

A system and method for producing a porous electrode with a high level of porosity, preferably mesoporosity, without the use of a binder. The electrode is formed by depositing a layer on a substrate from a colloidal suspension containing aggregated or agglomerated nanoparticles. Deposition methods include electrophoresis, ink-jet printing, doctor blade, roll coating, curtain coating, or dip-coating. The process includes drying and may involve additional consolidation steps such as pressing and/or heat treatment to enhance structural integrity, electrical conductivity, and adhesion. The heat treatment induces partial coalescence of nanoparticles, creating a three-dimensional porous structure that facilitates ion mobility. A thin coating of an electrically insulating or ion-conductive material may be applied to reduce interfacial reactions. The resulting porous electrode may be used in energy storage applications, such as lithium-ion batteries. The invention also includes a method for manufacturing batteries utilizing these electrodes and related battery designs.

CPC Classifications