Recycled aluminum alloys for use in current collectors in lithium ion batteries

Abstract

A battery component is described that includes a current collector and a coating disposed on at least a portion of a surface of the current collector. The current collector may include a recycled composition aluminum alloy. In some examples, the current collector may include 50% to 100% of a recycled aluminum composition. The recycle component aluminum alloy may be, for example, a 3xxx series aluminum alloy or a 5xxx series aluminum alloy.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 366,556, filed on June 17, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure relates generally to metallurgy and, more particularly, to improving battery current collectors and other components with recycled aluminum alloys. Background Art

[0004] In conventional lithium-ion batteries, aluminum is used as the cathode current collector. Typically, the cathode current collector comprises an aluminum alloy containing relatively large amounts or extremely pure aluminum. In contrast, the anode current collector typically comprises copper. These materials are often used because they have high electrical conductivity and electrochemical stability at the potentials encountered in their respective electrodes. Summary of the invention

[0005] The term embodiment and similar terms are intended to refer broadly to the subject matter of the present disclosure and the entirety of the following claims. Statements containing these terms should not be understood to limit the subject matter described herein, or to limit the meaning or scope of the following claims. The embodiments of the present disclosure covered herein are defined by the following claims rather than by this disclosure. This disclosure is a high-level overview of various aspects of the present disclosure and introduces some of the concepts further described in the following detailed description section. This disclosure is neither intended to identify the key or essential features of the claimed subject matter nor is it intended to be used independently to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of the present disclosure, any or all drawings, and each claim.

[0006] Environmental concerns call for increasing the recycled content in aluminum alloy products. For example, recycled content aluminum alloys are commonly used in beverage cans. However, increasing the recycled content of aluminum alloy products used in lithium-ion batteries may reduce the stability of the aluminum alloy products and / or lithium-ion batteries, and may result in reduced battery performance, such as due to the lower conductivity of high recycled content aluminum.

[0007] Described herein are battery components, such as current collectors, that include recycled content aluminum alloys. In any example, the current collector may include 50% to 100% recycled aluminum content, such as 50% recycled aluminum content, 51% recycled aluminum content, 52% recycled aluminum content, 53% recycled aluminum content, 54% recycled aluminum content, 55% recycled aluminum content, 56% recycled aluminum content, 57% recycled aluminum content, 58% recycled aluminum content, 59% recycled aluminum content, 60% recycled aluminum content, 61% recycled aluminum content, 62% recycled aluminum content, 63% recycled aluminum content, 64% recycled aluminum content, 65% recycled aluminum content, 66% recycled aluminum content, 67% recycled aluminum content, 68% recycled aluminum content, 69% recycled aluminum content, 70% recycled aluminum content, 71% recycled aluminum content, 72% recycled aluminum content, 73% recycled aluminum content, 74% recycled aluminum content, 75% recycled aluminum content, 76% recycled aluminum content, 77% recycled aluminum content, 78% recycled aluminum content, 79% recycled aluminum content, 80% recycled aluminum content, 81% recycled aluminum content, 82% recycled aluminum content, 83% recycled aluminum content, 84% recycled aluminum content, 85% recycled aluminum content, 86% recycled aluminum content, 87% recycled aluminum content, 88% recycled aluminum content, 89% recycled aluminum content, 4% recycled aluminum content, 75% recycled aluminum content, 76% recycled aluminum content, 77% recycled aluminum content, 78% recycled aluminum content, 79% recycled aluminum content, 80% recycled aluminum content, 81% recycled aluminum content, 82% recycled aluminum content, 83% recycled aluminum content, 84% recycled aluminum content, 85% recycled aluminum content, 86% recycled aluminum content, 87% recycled aluminum content, 88% recycled aluminum content, 89% recycled aluminum content, 90% recycled aluminum content, 91% recycled aluminum content, 92% recycled aluminum content, 93% recycled aluminum content, 94% recycled aluminum content, 95% recycled aluminum content, 96% recycled aluminum content, 97% recycled aluminum content, 98% recycled aluminum content, 99% recycled aluminum content, or 100% recycled aluminum content.

[0008] In some examples, the current collector may include a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy. In some examples, the current collector does not include a 1xxx series aluminum alloy or an 8xxx series aluminum alloy. In any example, the thickness of the current collector may be 0.005mm to 0.5mm, such as 0.005mm to 0.025mm, 0.025mm to 0.05mm, 0.05mm to 0.075mm, 0.075mm to 0.1mm, 0.1mm to 0.125mm, 0.125mm to 0.15mm, 0.15mm to 0.175mm, 0.175mm to 0.2mm, 0.2mm to 0.225mm m, 0.225mm to 0.25, 0.25mm to 0.275mm, 0.275mm to 0.3mm, 0.3mm to 0.325mm, 0.325mm to 0.35mm, 0.35mm to 0.375mm, 0.375mm to 0.4mm, 0.4mm to 0.425mm, 0.425mm to 0.45mm, 0.45mm to 0.475mm, or 0.475mm to 0.5mm.

[0009] In any example, the current collector may contain 50 wt % to 99.999 wt % Al. For example, the current collector may contain 50 wt % to 60 wt % Al, 50 wt % to 60 wt % Al, 50 wt % to 70 wt % Al, 50 wt % to 80 wt % Al, 50 wt % to 90 wt % Al, 50 wt % to 99.999 wt % Al, 60 wt % to 70 wt % Al, 60 wt % to 80 wt % Al, 60 wt % to 90 wt % Al, 60 wt % to 99.999 wt % Al, 70 wt % to 80 wt % Al, 70 wt % to 90 wt % Al, 70 wt % to 99.999 wt % Al, 80 wt % to 90 wt % Al, 80 wt % to 99.999 wt % Al, or 90 wt % to 99.999 wt % Al.

[0010] Optionally, a coating may be provided on at least a portion of the surface of the current collector. In any example, the coating may include a carbonaceous material. Examples of carbonaceous materials may include carbon black materials or Ketjen black materials. The coating may have a thickness of 5 nm to 100 μm, such as 5 nm to 50 nm, 50 nm to 100 nm, 100 nm to 150 nm, 150 nm to 200 nm, 200 nm to 250 nm, 250 nm to 300 nm, 300 nm to 350 nm, 350 nm to 400 nm, 400 nm to 450 nm, 450 nm to 500 nm, 500 nm to 550 nm, 550 nm to 600 nm, 650 nm to 700 nm, 700 nm to 750 nm, 750 nm to 800 nm, 800 nm to 850 nm, 850 nm to 900 nm. The coating may be applied to the surface of the current collector in an amount of 100 to 200 nm, 900 to 950 nm, 950 nm to 1 μm, 1 μm to 5 μm, 5 μm to 10 μm, 10 μm to 15 μm, 15 μm to 20 μm, 20 μm to 25 μm, 25 μm to 30 μm, 30 μm to 35 μm, 35 μm to 40 μm, 40 μm to 45 μm, 45 μm to 50 μm, 50 μm to 55 μm, 55 μm to 60 μm, 60 μm to 65 μm, 65 μm to 70 μm, 75 μm to 80 μm, 80 μm to 85 μm, 85 μm to 90 μm, 90 μm to 95 μm or 95 μm to 100 μm. Optionally, the coating may completely coat the surface of the current collector. Alternatively, the coating may partially coat the surface of the current collector. In any example, the coating may include multiple layers of coating.

[0011] In any example, the current collector may have one or more characteristics that are altered during the metal coating process to produce the coating. The one or more characteristics may include the surface area of ​​the current collector, the surface roughness of the current collector, the surface oxide layer, electrical conductivity, thermal conductivity, corrosion resistance, chemical reactivity, electrolyte reactivity, active material reactivity, wetting properties, or adhesion properties. The electrical conductivity of the current collector may include 30% IACS to 65% IACS, such as 30% to 31% IACS, 31% to 32% IACS, 33% to 34% IACS, 34% to 35% IACS, 35% to 36% IACS, 36% to 37% IACS, 37% to 38% IACS, 38% to 39% IACS, 40% to 41% IACS, 41% to 42% IACS, 42% to 43% IACS, 43% to 44% IACS, 44% to 45% IACS, 45% to 46% IACS, 46% to 47% IACS, 47% to 48% IACS, 48% to 49% IACS, 49% to 50% IACS, 50% to 51% IACS, IACS, 51% IACS to 52% IACS, 52% IACS to 53% IACS, 53% IACS to 54% IACS, 54% IACS to 55% IACS, 55% IACS to 56% IACS, 56% IACS to 57% IACS, 57% IACS to 58% IACS, 58% IACS to 59% IACS, 59% IACS to 60% IACS, 60% IACS to 61% IACS, 61% IACS to 62% IACS, 62% IACS to 63% IACS, 63% IACS to 64% IACS, 64% IACS to 65% IACS.

[0012] In some aspects, methods are described herein, such as methods of manufacturing battery components from recycled component aluminum alloys. An exemplary method of this aspect includes: providing a current collector comprising a recycled component aluminum alloy; and subjecting the surface of the current collector to a coating process to produce a coating on at least a portion of the surface of the current collector. In some examples, the method also includes subjecting the current collector or the coating to a further coating process to form a conductive layer. The conductive layer may include one or more of a carbonaceous material or a binder. In any example, the coating process may include an immersion coating process or a roll-to-roll coating process. In any example, the coating process may include plasma-assisted physical vapor deposition, plasma-activated physical vacuum deposition, plasma spray physical vapor deposition, vacuum plasma spray, metal gun spray deposition, plasma spray, plasma transfer wire arc spray, cold spray, electrochemical deposition, chemical deposition, sputtering, dip coating, or any combination thereof.

[0013] The current collectors made by the methods of this aspect may include any current collector described herein.

[0014] Other objects and advantages will become apparent from the following detailed description given by way of non-limiting example. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The description makes reference to the following drawings, in which the use of like reference numerals in different drawings is intended to indicate like or similar components.

[0016] Figure 1 A schematic overview of an example method for making a recycled content aluminum alloy product is provided.

[0017] Figure 2 A schematic cross-sectional illustration of an example current collector comprising a recycled content aluminum alloy and a coating is provided.

[0018] Figure 3 A schematic cross-sectional illustration of an example current collector comprising a recycled content aluminum alloy in a lithium-ion battery is provided. DETAILED DESCRIPTION

[0019] Battery components are described herein, such as current collectors comprising recycled content aluminum alloys, optionally wherein a coating is disposed on at least a portion of a surface of the current collector. In various examples, the recycled content aluminum alloys used in the methods and products described herein include 2xxx series aluminum alloys, 3xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, or 7xxx series aluminum alloys.

[0020] In the context of lithium or lithium-ion batteries, relatively pure aluminum alloys (such as 1xxx series aluminum alloys or 8xxx series aluminum alloys) are generally used as current collectors on the cathode side. However, using a current collector made of a recycled component aluminum alloy may be more sustainable than using a relatively pure aluminum alloy. In some examples, depending on the non-aluminum materials present in the recycled component aluminum alloy, the current collector made of the recycled component aluminum alloy may have improved stability, conductivity, and lifespan. In other examples, properties such as stability and conductivity may be reduced due to the use of recycled component aluminum alloys in the current collector.

[0021] For example, the conductivity of the recycled content aluminum alloy can be 30% to 50% of the conductivity of a relatively pure aluminum alloy (such as an aluminum alloy with 99.99% or more Al). The use of recycled content aluminum alloys, which may reduce conductivity in some cases, can counter the conventional teaching of requiring high conductivity by providing improved sustainability of aluminum products. In addition, a coating can be provided on the current collector to protect non-aluminum elements within the recycled content aluminum alloy from contacting lithium in a lithium-ion battery. The coating can prevent or limit corrosion and degradation of the current collector, and can improve the stability and conductivity of the current collector.

[0022] Definition and Description:

[0023] As used herein, the terms "invention," "the invention," "this invention," and "present invention" are intended to broadly refer to all subject matter of this patent application and the appended claims. Statements containing these terms should not be construed as limiting the subject matter described herein, or limiting the meaning or scope of the following patent claims.

[0024] In this specification, reference is made to alloys identified by AA numbers and other related designations such as "Series" or "7xxx". To understand the number designation system most commonly used to name and identify aluminum and its alloys, see "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot", both published by the Aluminum Association.

[0025] As used herein, the thickness of a plate is generally greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0026] As used herein, the thickness of the Saudi board (also referred to as a thin plate type board) is generally about 4 mm to about 15 mm. For example, the thickness of the Saudi board can be about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm or about 15 mm.

[0027] As used herein, thin plate generally refers to an aluminum product having a thickness of less than about 4 mm. For example, the thickness of the thin plate may be less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0028] Reference may be made to alloy tempers or conditions in this application. For understanding the most commonly used alloy temper descriptions, please refer to "American National Standards (ANSI) H35 on Alloy and Temper Designation Systems". F condition or temper refers to a manufactured aluminum alloy. O condition or temper refers to an aluminum alloy after annealing. Hxx condition or temper (also referred to herein as H temper) refers to a non-heat-treatable aluminum alloy that has been subjected to or not subjected to heat treatment (e.g., annealing) after cold rolling. Suitable H tempers include HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8 or HX9 tempers. T1 condition or temper refers to an aluminum alloy that has been cooled from hot working and subjected to natural aging treatment (e.g., at room temperature). T2 condition or temper refers to an aluminum alloy that has been cooled from hot working, cold worked and subjected to natural aging treatment. T3 condition or temper refers to an aluminum alloy that has been subjected to solution heat treatment, cold working and natural aging treatment. T4 condition or temper refers to an aluminum alloy that has been subjected to solution heat treatment and natural aging treatment. The T5 temper or temper refers to aluminum alloys that have been cooled from hot working and artificially aged (at elevated temperatures). The T6 temper or temper refers to aluminum alloys that have been solution heat treated and artificially aged. The T7 temper or temper refers to aluminum alloys that have been solution heat treated and artificially aged. The T8x temper or temper refers to aluminum alloys that have been solution heat treated, cold worked, and artificially aged. The T9 temper or temper refers to aluminum alloys that have been solution heat treated, artificially aged, and cold worked. The W temper or temper refers to aluminum alloys after solution heat treatment.

[0029] As used herein, terms such as "cast metal product", "cast product", "cast aluminum alloy product" and the like are interchangeable and refer to products produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by using a twin-belt caster, a twin-roll caster, a block caster or any other continuous casting machine), electromagnetic casting, hot top casting or any other casting method.

[0030] As used herein, "room temperature" may include a temperature from about 15° C. to about 30° C., such as about 15° C., about 16° C., about 17° C., about 18° C., about 19° C., about 20° C., about 21° C., about 22° C., about 23° C., about 24° C., about 25° C., about 26° C., about 27° C., about 28° C., about 29° C., or about 30° C. As used herein, "ambient conditions" may include a temperature of approximately room temperature, a relative humidity of about 20% to about 100%, and an atmospheric pressure of about 975 millibars (mbar) to about 1050 mbar. For example, the relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, about 101%, about 102%, about 103%, about 104%, about 105%, about 106%, about 107%, about 108%, about 109%, about 110%, about 111%, about 112%, about 113%, about 114%, about 115%, about 116%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, about 100%, about 101%, about 102%, about 103%, about 104%, about 105%, about 106%, about 107%, about 108%, about 109%, about 110%, about 111%, about 112%, about 113%, about 114%, about 115%, about 116%, about 117%, about 118%, about 119%, about 120%, about 121%, about 122%, about 123%, about 124%, about 125%, about 126%, about 127%, about 128%, about 129%, about 130%, about 131%, about 132%, about 133%, about 134%, about 135%, about 136%, about 137%, about 138%, about 139%, about 140%, about 141%, about 142%, about 143%, about 144%, about 145%, about 146%, about 147%, about 148%, about 149%, about 150%, about For example, the atmospheric pressure may be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or any value therebetween.

[0031] All ranges disclosed herein should be understood to encompass any and all subranges included therein. For example, a specified range of "1 to 10" should be considered to include any and all subranges between a minimum of 1 and a maximum of 10 (and including 1 and 10); that is, all subranges start with a minimum of 1 or greater (e.g., 1 to 6.1) and end with a maximum of 10 or less (e.g., 5.5 to 10). Unless otherwise stated, when referring to the composition amount of an element, the expression "up to" means that the element is optional and includes zero percent composition of the particular element. Unless otherwise stated, all composition percentages are in weight percent (wt%).

[0032] As used herein, "a," "an," and "the" include both singular and plural references unless the context clearly indicates otherwise.

[0033] In the following examples, aluminum alloy products and parts thereof may be described in terms of their elemental composition in weight percent (wt%). In each alloy, the remainder is aluminum, with a maximum wt% of 0.15% for the sum of all impurities.

[0034] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the present invention and may themselves add other properties without departing from or significantly altering the alloys described herein or the properties of the alloys described herein.

[0035] Small amounts of unavoidable impurities, including materials or elements, may be present in the alloy due to the inherent properties of aluminum or leaching from contact with processing equipment. As described, some alloys may contain no more than about 0.25% by weight of any element other than alloying elements, incidental elements, and unavoidable impurities.

[0036] Methods of producing alloys and aluminum alloy products

[0037] Figure 1 A schematic overview of an example method for making a recycled content aluminum alloy product is provided. Figure 1 The method may begin at step 105, where a recycled content aluminum alloy 106 may be cast to produce a cast aluminum alloy product 107, such as an ingot or other cast product. At step 110, the cast aluminum alloy product 107 may be homogenized to form a homogenized aluminum alloy product 111. At step 115, the homogenized aluminum alloy product 111 may be subjected to one or more hot rolling passes and / or one or more cold rolling passes to form a rolled aluminum alloy product 112, which may correspond to an aluminum alloy article, such as an aluminum alloy plate, an aluminum alloy slat, or an aluminum alloy sheet. Optionally, the rolled aluminum alloy product 112 may be subjected to one or more forming or stamping processes to form an aluminum alloy article.

[0038] The recycled component aluminum alloy described herein can be cast using any suitable casting method known to those of ordinary skill in the art. As several non-limiting examples, the casting process may include a direct chill (DC) casting process or a continuous casting (CC) process. The continuous casting system may include a pair of moving relative casting surfaces (e.g., moving relative belts, rollers or blocks), a casting cavity between the moving relative casting surfaces, and a molten metal injector. The molten metal injector may have an end opening from which the molten metal may leave the molten metal injector and be injected into the casting cavity.

[0039] The cladding layer may be attached to the core layer by any means known to those of ordinary skill in the art to form a clad product. For example, the cladding layer may be attached to the core layer by direct chill co-casting (i.e., fusion casting) as described in, for example, U.S. Patent Nos. 7,748,434 and 8,927,113, both of which are incorporated herein by reference in their entirety; hot-rolled and cold-rolled composite cast ingots as described in U.S. Patent No. 7,472,740, which are incorporated herein by reference in their entirety; or roll-bonded to achieve metallurgical bonding between the core and the cladding. The initial and final dimensions of the clad aluminum alloy product may be determined by the desired properties of the overall final product.

[0040] The roll bonding process can be performed in different ways. For example, the roll bonding process can include both hot rolling and cold rolling. In addition, the roll bonding process can be a one-step process or a multi-step process, in which the material is reduced in size during successive rolling steps. The individual rolling steps can optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, heating steps, cooling steps, etc.

[0041] The cast ingot, cast slab or other cast product may be processed by any suitable means. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment and optional pre-aging steps.

[0042] In the homogenization step, the cast product is heated to a temperature ranging from about 400°C to about 560°C. For example, the cast product may be heated to a temperature of about 400°C, about 410°C, about 420°C, about 430°C, about 440°C, about 450°C, about 460°C, about 470°C, about 480°C, about 490°C, about 490°C, about 500°C, about 510°C, about 520°C, about 520°C, about 540°C, about 550°C, or about 560°C. In some examples, homogenization is performed at a temperature within 50°C of the solidus temperature of the cast product or its alloy. The product is then allowed to soak (i.e., maintained at the indicated temperature) for a period of time to form a homogenized product. In some examples, the total time for the homogenization step (including the heating stage and the soaking stage) may be up to 24 hours. For example, for the homogenization step, the product may be heated to up to 500°C and soaked for a total time of up to 18 hours. Optionally, for the homogenization step, the product may be heated to less than 490°C and homogenized for a total time greater than 18 hours. In some cases, the homogenization step includes multiple processes. In some non-limiting examples, the homogenization step includes heating the cast product to a first temperature for a first period of time, and then heating to a second temperature for a second period of time. For example, the cast product may be heated to about 465°C for about 3.5 hours, and then heated to about 480°C for about 6 hours.

[0043] After the homogenization step, a hot rolling step may be performed. Before starting the hot rolling, the homogenized product may be allowed to cool to a temperature between 300° C. and 450° C. For example, the homogenized product may be allowed to cool to a temperature between 325° C. and 425° C. or from 350° C. to 400° C. The homogenized product may then be hot rolled at a temperature between 300°C and 450°C to form a hot rolled plate, hot rolled satur plate or hot rolled sheet having a specification between 3 mm and 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm or any value therebetween).

[0044] Optionally, the cast product may be a continuously cast product which may be allowed to cool to a temperature between 300° C. and 450° C. For example, the continuously cast product may be allowed to cool to a temperature between 325° C. and 425° C. or from 350° C. to 400° C. The continuously cast product may then be hot rolled at a temperature between 300° C. and 450° C. to form a hot rolled plate, hot rolled satur plate or hot rolled sheet having a specification between 3 mm and 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm or any value therebetween). During hot rolling, temperature and other operating parameters may be controlled so that the temperature of the hot rolled intermediate product does not exceed 470°C, does not exceed 450°C, does not exceed 440°C, or does not exceed 430°C when leaving the hot rolling mill.

[0045] Cold rolling mills can be used to cold roll cast, homogenized or hot rolled products into thinner products, such as cold rolled sheets. The specifications of the cold rolled products can optionally be between about 0.5 and 10 mm, for example, between about 0.7 and 6.5 mm. Optionally, the cold rolled products can have the following specifications: 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm or 10.0 mm. Cold rolling may be performed to obtain a final gauge thickness that represents a gauge reduction of up to 85% (e.g., a reduction of up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, or up to 85%) compared to the gauge before cold rolling began. Optionally, an intermediate annealing step may be performed during the cold rolling step, such as applying a first cold rolling process, followed by an annealing process (intermediate annealing), and then a second cold rolling process. The intermediate annealing step may be performed at a temperature of about 300°C to about 450°C (e.g., about 310°C, about 320°C, about 330°C, about 340°C, about 350°C, about 360°C, about 370°C, about 380°C, about 390°C, about 400°C, about 410°C, about 420°C, about 430°C, about 440°C, or about 450°C). In some cases, the intermediate annealing step includes multiple processes. In some non-limiting examples, the intermediate annealing step includes heating the partially cold rolled product to a first temperature for a first period of time and then heating to a second temperature for a second period of time. For example, the partially cold rolled product may be heated to about 410° C. for about 1 hour and then heated to about 330° C. for about 2 hours.

[0046] Subsequently, the cast, homogenized or rolled product may optionally be subjected to a solution heat treatment step. The solution heat treatment step may be any treatment suitable for thin plates that results in solubilization of soluble particles. The cast, homogenized or rolled product may be heated to a peak metal temperature (PMT) of up to 590°C (e.g., from 400°C to 590°C), and soaked for a period of time at the PMT to form a hot product. For example, the cast, homogenized or rolled product may be soaked at 480°C for up to 30 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes, 20 minutes, 25 minutes or 30 minutes) of soaking time. After heating and soaking, the hot product is rapidly cooled to a temperature between 500°C and 200°C, such as at a rate greater than 200°C / second, to form a heat-treated product. In one example, the hot product is cooled to a temperature between 450°C and 200°C at a quenching rate greater than 200°C / second. Optionally, in other cases, the cooling rate may be faster.

[0047] After quenching, the heat treated product may optionally be pre-aged by reheating before coiling. The pre-aging treatment may be performed at a temperature of about 70°C to about 125°C for a period of up to 6 hours. For example, the pre-aging treatment may be performed at a temperature of about 70°C, about 75°C, about 80°C, about 85°C, about 90°C, about 95°C, about 100°C, about 105°C, about 110°C, about 115°C, about 120°C, or about 125°C. Optionally, the pre-aging treatment may be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. The pre-aging treatment may be performed by passing the heat treated product through a heating device, such as a device that generates or emits radiant heat, convection heat, induction heat, infrared heat, etc.

[0048] Cast products described herein can be used to manufacture products or other suitable products in the form of thin plates, plates. For example, the plate comprising products as described herein can be prepared in the following manner: in a homogenization step, ingots are processed or cast products are cast in a continuous casting machine, followed by a hot rolling step. In the hot rolling step, the cast products can be hot rolled to a specification of 200 mm thick or less (for example, about 10 mm to about 200 mm). For example, the cast products can be hot rolled into a plate with the following final specification thickness: about 10 mm to about 175 mm, about 15 mm to about 150 mm, about 20 mm to about 125 mm, about 25 mm to about 100 mm, about 30 mm to about 75 mm, or about 35 mm to about 50 mm. In some cases, the plate can be rolled into a thinner metal product, such as a thin plate.

[0049] In some examples, a rolled aluminum alloy product 112 may be provided or prepared for use as a current collector. The surface of the current collector may be subjected to a coating process to produce a coating on at least a portion of the surface of the current collector. The coating process may be a metal coating process that changes one or more properties of the current collector. The properties may include the surface area of ​​the current collector, the surface roughness of the current collector, a surface oxide layer, electrical conductivity, thermal conductivity, corrosion resistance, chemical reactivity, electrolyte reactivity, active material reactivity, wetting properties, or adhesion properties.

[0050] In any example, the current collector or the resulting coating may be subjected to a further coating process to form a conductive layer. The conductive layer may include one or more of a carbonaceous material or a binder. Examples of carbonaceous materials may include carbon black materials or Ketjen black materials. In some examples, the coating process may be an immersion coating process or a roll-to-roll coating process.

[0051] In any example, the current collector and the coating may be subjected to a further coating process, which may form an electrode active material layer on the coating. In any example, the coating process may be plasma assisted physical vapor deposition, plasma activated physical vacuum deposition, plasma spray physical vapor deposition, vacuum plasma spray, metal gun spray deposition, plasma spray, plasma transferred wire arc spray, cold spray, electrochemical deposition, chemical deposition, sputtering, dip coating, immersion coating process, roll-to-roll coating process, or any combination thereof.

[0052] metal alloy

[0053] In any example, the metal used in the method and product described herein includes an aluminum alloy, such as a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy. In some examples, the material used in the method and product described herein includes a non-ferrous material, including aluminum, an aluminum alloy, magnesium, a magnesium-based material, a magnesium alloy, a magnesium composite material, titanium, a titanium-based material, a titanium alloy, copper, a copper-based material, a composite material, a sheet for a composite material, or any other suitable metal, non-metal or material combination. Monolithic materials and non-monolithic materials (such as rolled bonded materials, clad alloys, cladding layers, composite materials such as but not limited to carbon fiber-containing materials) or various other materials may also be used with the method and product described herein. In some examples, an aluminum alloy containing iron may be used with the method and product described herein.

[0054] As non-limiting examples, exemplary 2xxx series aluminum alloys for use in the methods and products described herein may include AA2001, AA2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2015, AA2016, AA2017, AA2018, AA2019, AA2020, AA2021 4. AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA221 9. AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324 , AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028 C. AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, A A2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA20 95, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099 or AA2199.

[0055] Non-limiting exemplary 3xxx series aluminum alloys for use in the methods and products described herein may include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005 AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.

[0056] Non-limiting exemplary 4xxx series aluminum alloys for use in the methods and products described herein may include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0057] Non-limiting exemplary 5xxx series aluminum alloys for use in the methods and products described herein may include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119 ... A5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA504 9. AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, A A5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5 556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA51 82. AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187 or AA5088.

[0058] Non-limiting exemplary 6xxx series aluminum alloys for use in the methods and products described herein may include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306 ... A6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA 6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA60 28. AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA605 3. AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A , AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0059] Non-limiting exemplary 7xxx series aluminum alloys for use in the methods and products described herein may include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028 ,AA7030,AA7031,AA7033,AA7035,AA7035A,AA7046,AA7046A,AA7003,AA7004,AA7005,AA70 09. AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA71 29. AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7 049, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, A AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0060] Battery Parts

[0061] The recycled component aluminum alloy products described herein (such as foils or sheets) can be used to manufacture battery components, such as electronic substrates, which can be suitable for use as current collectors or devices (such as electrodes, electrochemical cells or capacitors) incorporating such current collectors. In any example, the recycled component aluminum alloy can be provided as a thin plate or foil, but is generally referred to as a layer in the context of the current collector herein. In order to be used as a current collector, the recycled component aluminum alloy layer can be coated with a coating or otherwise contacted with the coating, which can also be referred to as a protective layer or conductive protective layer herein. The recycled component aluminum alloy can alternatively be provided as a coating on the coating, which can optionally include a metal or metal alloy foil. In some cases, both the recycled component aluminum alloy and the coating can include a foil.

[0062] Figure 2A schematic cross-sectional illustration of an example current collector 200 is provided that includes a recycled content aluminum alloy 205 and a coating 210 disposed on a surface of the recycled content aluminum alloy 205. In the current collector 200, the coating 210 is shown as being in contact with only one surface or side of the recycled content aluminum alloy 205, but other configurations may also be used, such as configurations in which the coating 210 is in contact with different edges, surfaces, or faces of the recycled content aluminum alloy 205. In any example, the thickness of the current collector 200 may be 0.005 mm to 0.5 mm. For example, the thickness of the current collector 200 may be 0.005 mm to 0.5 mm, such as 0.005 mm to 0.025 mm, 0.025 mm to 0.05 mm, 0.05 mm to 0.075 mm, 0.075 mm to 0.1 mm, 0.1 mm to 0.125 mm, 0.125 mm to 0.15 mm, 0.15 mm to 0.175 mm, 0.175 mm to 0.2 mm, 0.2 mm to 0.225 mm. , 0.225mm to 0.25mm, 0.25mm to 0.275mm, 0.275mm to 0.3mm, 0.3mm to 0.325mm, 0.325mm to 0.35mm, 0.35mm to 0.375mm, 0.375mm to 0.4mm, 0.4mm to 0.425mm, 0.425mm to 0.45mm, 0.45mm to 0.475mm, or 0.475mm to 0.5mm.

[0063] In any example, the recycled content aluminum alloy 205 may include 50% to 100% recycled aluminum content. For example, the recycled content aluminum alloy 205 may include 50% recycled aluminum content, 51% recycled aluminum content, 52% recycled aluminum content, 53% recycled aluminum content, 54% recycled aluminum content, 55% recycled aluminum content, 56% recycled aluminum content, 57% recycled aluminum content, 58% recycled aluminum content, 59% recycled aluminum content, 60% recycled aluminum content, 61% recycled aluminum content, 62% recycled aluminum content, 63% recycled aluminum content, 64% recycled aluminum content, 65% recycled aluminum content, 66% recycled aluminum content, 67% recycled aluminum content, 68% recycled aluminum content, 69% recycled aluminum content, 70% recycled aluminum content, 71% recycled aluminum content, 72% recycled aluminum content, 73% recycled aluminum content, 74% recycled aluminum content, %, 75% recycled aluminum content, 76% recycled aluminum content, 77% recycled aluminum content, 78% recycled aluminum content, 79% recycled aluminum content, 80% recycled aluminum content, 81% recycled aluminum content, 82% recycled aluminum content, 83% recycled aluminum content, 84% recycled aluminum content, 85% recycled aluminum content, 86% recycled aluminum content, 87% recycled aluminum content, 88% recycled aluminum content, 89% recycled aluminum content, 90% recycled aluminum content, 91% recycled aluminum content, 92% recycled aluminum content, 93% recycled aluminum content, 94% recycled aluminum content, 95% recycled aluminum content, 96% recycled aluminum content, 97% recycled aluminum content, 98% recycled aluminum content, 99% recycled aluminum content, or 100% recycled aluminum content.

[0064] In any example, the recycled content aluminum alloy 205 can include 50 wt % to 99.999 wt % aluminum (Al). For example, the recycled content aluminum alloy 205 may include 50 wt % to 60 wt % Al, 50 wt % to 60 wt % Al, 50 wt % to 70 wt % Al, 50 wt % to 80 wt % Al, 50 wt % to 90 wt % Al, 50 wt % to 99.999 wt % Al, 60 wt % to 70 wt % Al, 60 wt % to 80 wt % Al, 60 wt % to 90 wt % Al, 60 wt % to 99.999 wt % Al, 70 wt % to 80 wt % Al, 70 wt % to 90 wt % Al, 70 wt % to 99.999 wt % Al, 80 wt % to 90 wt % Al, 80 wt % to 99.999 wt % Al, or 90 wt % to 99.999 wt % Al.

[0065] In some cases, the recycled content aluminum alloy 205 may be a 3xxx series aluminum alloy or a 5xxx series aluminum alloy. In other cases, the recycled content aluminum alloy 205 may be a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy. In some examples, the recycled content aluminum alloy 205 may not include a 1xxx series aluminum alloy or an 8xxx series aluminum alloy.

[0066] The coating 210 can be used to prevent materials from directly contacting the recycled component aluminum alloy 205, such as in the current collector 200 application of a battery. In some examples, the coating 210 can be used to block or otherwise prevent the transmission of certain materials, such as limiting the contact of those materials with the underlying recycled component aluminum alloy 205. Optionally, the coating 210 can be conductive and allow electrons to be transferred to the recycled component aluminum alloy. In some examples, the coating 210 can be a carbonaceous material. Examples of carbonaceous materials can include carbon black materials or Ketjen black materials.

[0067] The coating 210 may have any suitable thickness. Example thicknesses may be 5 nm to 100 μm, such as 5 nm to 50 nm, 50 nm to 100 nm, 100 nm to 150 nm, 150 nm to 200 nm, 200 nm to 250 nm, 250 nm to 300 nm, 300 nm to 350 nm, 350 nm to 400 nm, 400 nm to 450 nm, 450 nm to 500 nm, 500 nm to 550 nm, 550 nm to 600 nm, 650 nm to 700 nm, 700 nm to 750 nm, 750 nm to 800 nm, 800 nm to 850 nm, 850 nm to 900 nm. 0nm, 900nm to 950nm, 950nm to 1μm, 1μm to 5μm, 5μm to 10μm, 10μm to 15μm, 15μm to 20μm, 20μm to 25μm, 25μm to 30μm, 30μm to 35μm, 35μm to 40μm, 40μm to 45μm, 45μm to 50μm, 50μm to 55μm, 55μm to 60μm, 60μm to 65μm, 65μm to 70μm, 75μm to 80μm, 80μm to 85μm, 85μm to 90μm, 90μm to 95μm, or 95μm to 100μm.

[0068] Some example techniques for producing the coating 210 may include, but are not limited to, a physical deposition process, a sputtering deposition process, an evaporation deposition process, a chemical deposition process, an electrodeposition process, an electroplating process, a chemical vapor deposition process, or an atomic layer deposition process.

[0069] In some cases, it may be desirable to achieve partial or complete encapsulation of the recycled content aluminum alloy 205 by the coating 210. For example, the coating 210 may partially coat the surface, or may completely coat the surface. This configuration may be achieved, for example, by using a non-directional deposition technique (such as an electrodeposition process), which may be a solution phase process and results in the coating 210 completely coating or encapsulating the recycled content aluminum alloy 205. In some cases, the coating 210 may be a multi-layer coating. Each layer of the multi-layer coating may have the same or different composition as the other layers.

[0070] The coating 210 may be produced on the recycled content aluminum alloy 205 in a metal coating process that changes one or more properties of the recycled content aluminum alloy 205. The one or more properties may include the surface area of ​​the recycled content aluminum alloy 205, the surface roughness of the recycled content aluminum alloy 205, the surface oxide layer, the electrical conductivity, the thermal conductivity, the corrosion resistance, the active material reactivity, the wetting characteristics, or the adhesion characteristics. It may be beneficial for the coating 210 or the current collector 200 as a whole to have an electrical conductivity of 30% IACS to 65% IACS. For example, the electrical conductivity of the current collector 200 may be 30% IACS to 65% IACS, such as 30% to 31% IACS, 31% to 32% IACS, 33% to 34% IACS, 34% to 35% IACS, 35% to 36% IACS, 36% to 37% IACS, 37% to 38% IACS, 38% to 39% IACS, 40% to 41% IACS, 41% to 42% IACS, 42% to 43% IACS, 43% to 44% IACS, 44% to 45% IACS, 45% to 46% IACS, 46% to 47% IACS, 47% to 48% IACS, 48% to 49% IACS, 49% to 50% IACS, 50% to 51% IACS, IACS to 51% IACS, 51% IACS to 52% IACS, 52% IACS to 53% IACS, 53% IACS to 54% IACS, 54% IACS to 55% IACS, 55% IACS to 56% IACS, 56% IACS to 57% IACS, 57% IACS to 58% IACS, 58% IACS to 59% IACS, 59% IACS to 60% IACS, 60% IACS to 61% IACS, 61% IACS to 62% IACS, 62% IACS to 63% IACS, 63% IACS to 64% IACS, 64% IACS to 65% IACS.

[0071] Methods of using the disclosed recycled content aluminum alloy products

[0072] The recycled content aluminum alloy products described herein can be used in electronic applications. For example, the recycled content aluminum alloy products and methods described herein can be used to prepare components of electronic devices, including batteries, mobile phones, and tablet computers. In some examples, the recycled content aluminum alloy products can be used to prepare current collectors and electrodes used in electrochemical cells, capacitors, or batteries, which can be used in mobile phones, tablet computers, etc.

[0073] Figure 3 A schematic cross-sectional illustration of an example current collector including a recycled content aluminum alloy 305 in a lithium-ion battery 300 is provided. The lithium-ion battery 300 includes: a first electrode 302, which may correspond to a cathode in some examples; and a second electrode 304, which may correspond to an anode in some examples. The first electrode 302 of the lithium-ion battery 300 includes a first current collector 320. In some examples, the first current collector 320 may include a recycled content aluminum alloy. The first electrode 302 also includes a first active material 330, such as a cathode active material. The second electrode 304 of the lithium-ion battery 300 includes a recycled content aluminum alloy 305 (as a second current collector) and a coating 310. The second electrode 304 also includes a second active material 315, such as an anode active material. Although the above reference is made to the uncoated current collector 320 and the current collector 306 including the coating 310, Figure 3 Lithium-ion battery 300 is depicted, but this configuration is not intended to be limiting, and one or both of current collector 320 and current collector 306 may or may not include a coating.

[0074] The lithium-ion battery 300 also includes a separator and / or an electrolyte, as shown in component 335. The separator and / or the electrolyte can be used to prevent the first electrode active material and the second electrode active material from contacting each other, while still allowing ions to be transmitted through during charging or discharging. An exemplary separator can be or include a non-reactive porous material, such as a polymer film, such as polypropylene, poly(methyl methacrylate), or polyacrylonitrile. An example electrolyte can be or include an organic solvent, such as ethylene carbonate, dimethyl carbonate, or diethyl carbonate, or a solid or ceramic electrolyte. The electrolyte can include a dissolved lithium salt, such as LiPF6, LiBF4, or LiClO4, as well as other additives.

[0075] The examples disclosed herein will be used to further illustrate various aspects of the present invention, but will not constitute any limitation to the present invention at the same time. On the contrary, it should be clearly understood that it may be necessary to resort to various embodiments, modifications and equivalents thereof that can be thought of by those skilled in the art after reading the description herein without departing from the spirit of the present invention. Unless otherwise stated, the examples and embodiments described herein can also utilize conventional procedures. Some programs are described herein for illustrative purposes.

[0076] Illustrative aspects

[0077] As used below, any reference to a series of aspects (e.g., “Aspects 1 to 4”) or an unlisted group of aspects (e.g., “any previous or subsequent aspect”) should be understood as a separate reference to each of those aspects (e.g., “Aspects 1 to 4” should be understood as “Aspect 1, Aspect 2, Aspect 3, or Aspect 4”).

[0078] Aspect 1 is a battery component comprising: a current collector comprising a recycled component aluminum alloy; and a coating disposed on at least a portion of a surface of the current collector.

[0079] Aspect 2 is the battery component of any preceding or subsequent aspect, wherein the current collector comprises 50% to 100% recycled aluminum content.

[0080] Aspect 3 is the battery component of any preceding or subsequent aspect, wherein the current collector comprises a 3xxx series aluminum alloy or a 5xxx series aluminum alloy.

[0081] Aspect 4 is the battery component of any preceding or subsequent aspect, wherein the thickness of the current collector is from 0.005 mm to 0.5 mm.

[0082] Aspect 5 is a battery component of any preceding or subsequent aspect, wherein the current collector does not comprise a 1xxx series aluminum alloy or an 8xxx series aluminum alloy.

[0083] Aspect 6 is the battery component of any preceding or subsequent aspect, wherein the current collector comprises a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

[0084] Aspect 7 is the battery component of any preceding or subsequent aspect, wherein the current collector comprises 50 wt % to 99.9 wt % Al.

[0085] Aspect 8 is the battery component of any preceding or subsequent aspect, wherein the current collector comprises 80 wt % to 99 wt % Al.

[0086] Aspect 9 is the battery component of any preceding or subsequent aspect, wherein the coating comprises a carbonaceous material.

[0087] Aspect 10 is the battery component of any preceding or subsequent aspect, wherein the carbonaceous material comprises a carbon black material or a Ketjen black material.

[0088] Aspect 11 is the battery component of any preceding or subsequent aspect, wherein the coating has a thickness of 5 nm to 100 μm.

[0089] Aspect 12 is the battery component of any preceding or subsequent aspect, wherein the coating completely coats the surface of the current collector, or wherein the coating partially coats the surface of the current collector.

[0090] Aspect 13 is the battery component of any preceding or subsequent aspect, wherein the coating comprises a multi-layer coating.

[0091] Aspect 14 is a battery component of any previous or subsequent aspect, wherein one or more properties of the collector are altered during a metal coating process to produce the coating on at least a portion of the surface of the collector, and wherein the one or more properties of the collector include the surface area of ​​the collector, the surface roughness of the collector, a surface oxide layer, electrical conductivity, thermal conductivity, corrosion resistance, chemical reactivity, electrolyte reactivity, active material reactivity, wetting properties, or adhesion properties.

[0092] Aspect 15 is the battery component of any preceding or subsequent aspect, wherein the conductivity of the current collector is from 30% IACS to 65% IACS.

[0093] Aspect 16 is a method of manufacturing a battery component, the method comprising: providing a current collector, wherein the current collector comprises a recycled component aluminum alloy; and subjecting a surface of the current collector to a coating process to produce a coating on at least a portion of the surface of the current collector.

[0094] Aspect 17 is the method of any preceding or subsequent aspect, wherein the coating process changes one or more properties of the current collector, such as surface properties.

[0095] Aspect 18 is the method of any preceding or subsequent aspect, wherein the one or more properties of the collector include the surface area of ​​the collector, the surface roughness of the collector, a surface oxide layer, electrical conductivity, thermal conductivity, corrosion resistance, chemical reactivity, electrolyte reactivity, active material reactivity, wetting properties, or adhesion properties.

[0096] Aspect 19 is the method of any preceding or subsequent aspect, further comprising: subjecting the current collector or the coating to a further coating process to form a conductive layer, wherein the conductive layer comprises one or more of a carbonaceous material or a binder.

[0097] Aspect 20 is the method of any preceding or subsequent aspect, wherein the coating process comprises an immersion coating process or a roll-to-roll coating process.

[0098] Aspect 21 is the method of any preceding or subsequent aspect, further comprising: subjecting the current collector and the coating to a further coating process to form an electrode active material layer on the coating.

[0099] Aspect 22 is the method of any preceding or subsequent aspect, wherein the coating process comprises plasma-assisted physical vapor deposition, plasma-activated physical vacuum deposition, plasma spray physical vapor deposition, vacuum plasma spray, metal gun spray deposition, plasma spray, plasma transferred wire arc spray, cold spray, electrochemical deposition, chemical deposition, sputtering, dip coating, immersion coating process, roll-to-roll coating process, or any combination thereof.

[0100] Aspect 23 is the method of any preceding or subsequent aspect, wherein the battery component is the battery component of any preceding aspect.

[0101] Aspect 24 is the battery component of any preceding or subsequent aspect, wherein the battery component is prepared according to the method of any preceding aspect.

[0102] Aspect 25 is a battery comprising the battery component of any preceding or subsequent aspect.

[0103] Aspect 26 is a battery of any previous aspect, comprising an anode active material; a cathode active material; and an electrolyte between the anode active material and the cathode active material, wherein the battery component is a current collector in electrical contact with the anode active material or the cathode active material.

[0104] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including the illustrated embodiments, is presented for illustration and description purposes only and is not intended to be exhaustive or limited to the precise forms disclosed. Numerous modifications, variations and uses of the present invention will be apparent to those skilled in the art.

Claims

1. A battery component, comprising: a current collector comprising a recycled content aluminum alloy; as well as A coating is disposed on at least a portion of a surface of the current collector.

2. The battery component of claim 1, wherein the current collector comprises 50% to 100% recycled aluminum content.

3. The battery component of claim 1, wherein the current collector comprises a 3xxx series aluminum alloy or a 5xxx series aluminum alloy. The battery component according to claim 1 , wherein the current collector has a thickness of 0.005 mm to 0.5 mm.

5. The battery component of claim 1, wherein the current collector does not comprise a 1xxx series aluminum alloy or an 8xxx series aluminum alloy.

6. The battery component of claim 1, wherein the current collector comprises a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

7. The battery component of claim 1, wherein the current collector comprises 50 wt% to 99.9 wt% Al.

8. The battery component of claim 1, wherein the current collector comprises 80 wt% to 99 wt% Al.

9. The battery component of claim 1, wherein the coating comprises a carbonaceous material.

10. The battery component according to claim 9, wherein the carbonaceous material comprises a carbon black material or a Ketjen black material.

11. The battery component according to claim 1, wherein the coating layer has a thickness of 5 nm to 100 μm.

12. The battery component of claim 1, wherein the coating completely coats the surface of the current collector, or wherein the coating partially coats the surface of the current collector.

13. The battery component of claim 1, wherein the coating comprises a multi-layer coating.

14. A battery component as described in claim 1, wherein one or more properties of the collector are changed during a metal coating process to produce the coating on at least a portion of the surface of the collector, and wherein the one or more properties of the collector include the surface area of ​​the collector, the surface roughness of the collector, a surface oxide layer, electrical conductivity, thermal conductivity, corrosion resistance, chemical reactivity, electrolyte reactivity, active material reactivity, wetting properties or adhesion properties.

15. The battery component of claim 14, wherein the conductivity of the current collector is 30% IACS to 65% IACS.

16. A method of manufacturing a battery component, the method comprising: providing a current collector, wherein the current collector comprises a recycled content aluminum alloy; as well as The surface of the current collector is subjected to a coating process to produce a coating on at least a portion of the surface of the current collector.

17. The method of claim 16, wherein the coating process changes one or more surface properties of the current collector.

18. The method of claim 17, wherein the one or more surface properties of the current collector include surface area of ​​the current collector, surface roughness of the current collector, a surface oxide layer, electrical conductivity, thermal conductivity, corrosion resistance, chemical reactivity, electrolyte reactivity, active material reactivity, wetting properties, or adhesion properties.

19. The method of claim 16, further comprising: The current collector or the coating is subjected to a further coating process to form a conductive layer, wherein the conductive layer comprises one or more of a carbonaceous material or a binder.

20. The method of claim 19, wherein the coating process comprises an immersion coating process or a roll-to-roll coating process.

21. The method of claim 16, further comprising: The current collector and the coating layer are subjected to a further coating process to form an electrode active material layer on the coating layer.

22. The method of claim 16, wherein the coating process comprises plasma assisted physical vapor deposition, plasma activated physical vacuum deposition, plasma spray physical vapor deposition, vacuum plasma spray, metal gun spray deposition, plasma spray, plasma transferred wire arc spray, cold spray, electrochemical deposition, chemical deposition, sputtering, dip coating, immersion coating process, roll-to-roll coating process, or any combination thereof.

23. The method of claim 16, wherein the battery component is a battery component as claimed in any one of claims 1 to 15.

24. The battery component according to any one of claims 1 to 15, prepared using the method according to any one of claims 16 to 22.

25. A battery comprising the battery component according to any one of claims 1 to 15 or 24.

26. The battery of claim 25, comprising: Anode active material; cathode active material; as well as an electrolyte between the anode active material and the cathode active material, wherein the battery component is a current collector in electrical contact with the anode active material or the cathode active material.

Images