Recycled aluminum alloy for use in a current collector of a lithium ion battery

Abstract

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

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit and priority of U.S. Provisional Application No. 63 / 366,556, filed on June 17, 2022, which is hereby incorporated by reference in its entirety.

[0002] The present disclosure generally relates to metallurgy, and more specifically, to improving current collectors and other components of batteries using recycled aluminum alloys.

Background Art

[0003] In conventional lithium - ion batteries, aluminum is used as the positive - electrode current collector. Generally, the positive - electrode current collector includes a relatively large amount of aluminum or an aluminum alloy containing very pure aluminum. In comparison, the negative - electrode current collector generally includes copper. These materials tend to be used due to their high conductivity and electrochemical stability at the potentials generated at each electrode.

Summary of the Invention

[0004] The term "embodiment" and similar terms are intended to broadly refer to all of the subject matter of the present disclosure and the following claims. Descriptions containing these terms are not intended to limit the subject matter described herein or the meaning or scope of the following claims. The embodiments of the present disclosure covered herein are not an abstract of this invention but are defined by the following claims. The summary of the invention is a high - level overview of various aspects of the present disclosure and introduces some of the concepts further explained in the "Modes for Carrying Out the Invention" section below. The summary of the invention is not intended to identify the important or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by referring to the entire specification of the present disclosure, any or all of the drawings, and the appropriate portions of each claim.

[0005] Due to concerns about the environment, there is a demand to increase the recycled material content in aluminum alloy products. For example, recycled aluminum alloys are commonly used in beverage cans. However, increasing the recycled material content in aluminum alloy products used in lithium-ion batteries can reduce the stability of the aluminum alloy products and / or lithium-ion batteries, and the battery performance may be reduced because the electrical conductivity of aluminum with a high recycling content is low.

[0006] This specification describes battery components such as current collectors that include recycled aluminum-containing alloys. In any example, the current collector may include a recycled aluminum content of 50% to 100%, for example, a recycled aluminum content of 50%, a recycled aluminum content of 51%, a recycled aluminum content of 52%, a recycled aluminum content of 53%, a recycled aluminum content of 54%, a recycled aluminum content of 55%, a recycled aluminum content of 56%, a recycled aluminum content of 57%, a recycled aluminum content of 58%, a recycled aluminum content of 59%, a recycled aluminum content of 60%, a recycled aluminum content of 61%, a recycled aluminum content of 62%, a recycled aluminum content of 63%, a recycled aluminum content of 64%, a recycled aluminum content of 65%, a recycled aluminum content of 66%, a recycled aluminum content of 67%, a recycled aluminum content of 68%, a recycled aluminum content of 69%, a recycled aluminum content of 70%, a recycled aluminum content of 71%, a recycled aluminum content of 72%, a recycled aluminum content of 73%, a recycled aluminum content of 74%, a recycled aluminum content of 75%, a recycled aluminum content of 76%, a recycled aluminum content of 77%, a recycled aluminum content of 78%, a recycled aluminum content of 79%, a recycled aluminum content of 80%, a recycled aluminum content of 81%, a recycled aluminum content of 82%, a recycled aluminum content of 83%, a recycled aluminum content of 84%, a recycled aluminum content of 85%, a recycled aluminum content of 86%, a recycled aluminum content of 87%, a recycled aluminum content of 88%, a recycled aluminum content of 89%, a recycled aluminum content of 90%, a recycled aluminum content of 91%, a recycled aluminum content of 92%, a recycled aluminum content of 93%, a recycled aluminum content of 94%, a recycled aluminum content of 95%, a recycled aluminum content of 96%, a recycled aluminum content of 97%, a recycled aluminum content of 98%, a recycled aluminum content of 99%, or a recycled aluminum content of 100%.

[0007] In some examples, the current collector may include an aluminum alloy of the 2xxx series, an aluminum alloy of the 3xxx series, an aluminum alloy of the 4xxx series, an aluminum alloy of the 5xxx series, an aluminum alloy of the 6xxx series, or an aluminum alloy of the 7xxx series. In some examples, the current collector does not include an aluminum alloy of the 1xxx series or an aluminum alloy of the 8xxx series. In any example, the current collector may have a thickness of 0.005 mm to 0.5 mm, for example, 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, 0.225 mm to 0.25, 0.25 mm to 0.275 mm, 0.275 mm to 0.3 mm, 0.3 mm to 0.325 mm, 0.325 mm to 0.35 mm, 0.35 mm to 0.375 mm, 0.375 mm to 0.4 mm, 0.4 mm to 0.425 mm, 0.425 mm to 0.45 mm, 0.45 mm to 0.475 mm, or 0.475 mm to 0.5 mm.

[0008] In any example, the current collector may include 50 wt.% to 99.999 wt.% of Al. For example, the current collector may include 50 wt.% to 60 wt.% of Al, for example, 50 wt.% to 60 wt.% of Al, 50 wt.% to 70 wt.% of Al, 50 wt.% to 80 wt.% of Al, 50 wt.% to 90 wt.% of Al, 50 wt.% to 99.999 wt.% of Al, 60 wt.% to 70 wt.% of Al, 60 wt.% to 80 wt.% of Al, 60 wt.% to 90 wt.% of Al, 60 wt.% to 99.999 wt.% of Al, 70 wt.% to 80 wt.% of Al, 70 wt.% to 90 wt.% of Al, 70 wt.% to 99.999 wt.% of Al, 80 wt.% to 90 wt.% of Al, 80 wt.% to 99.999 wt.% of Al, or 90 wt.% to 99.999 wt.% of Al.

[0009] Optionally, the coating layer can be disposed on at least a portion of the surface of the current collector. In any example, the coating layer can include a carbon-based material. Examples of carbon-based materials can include carbon black materials or ketjen black materials. The coating layer can have a thickness of 5 nm to 100 μm, for example, 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, 900 nm 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 layer can completely coat the surface of the current collector. Alternatively, the coating layer can partially coat the surface of the current collector. In any example, the coating layer can include a multilayer coating.

[0010] In any example, the current collector can have one or more properties that are modified by a metal coating process to produce a coating layer. The one or more features can include the surface area of the current collector, the surface roughness of the current collector, the surface oxide layer, the electrical conductivity, the thermal conductivity, the corrosion resistance, the chemical reactivity, the electrolyte reactivity, the active material reactivity, the wetting characteristics, or the adhesion characteristics. The conductivity of the current collector can have a value between 30% IACS and 65% IACS, for example, 30% IACS - 31% IACS, 31% IACS - 32% IACS, 33% IACS - 34% IACS, 34% IACS - 35% IACS, 35% IACS - 36% IACS, 36% IACS - 37% IACS, 37% IACS - 38% IACS, 38% IACS - 39% IACS, 40% IACS - 41% IACS, 41% IACS - 42% IACS, 42% IACS - 43% IACS, 43% IACS - 44% IACS, 44% IACS - 45% IACS, 45% IACS - 46% IACS, 46% IACS - 47% IACS, 47% IACS - 48% IACS, 48% IACS - 49% IACS, 49% IACS - 50% IACS, 50% IACS - 51% IACS, 51% IACS - 52% IACS, 52% IACS - 53% IACS, 53% IACS - 54% IACS, 54% IACS - 55% IACS, 55% IACS - 56% IACS, 56% IACS - 57% IACS, 57% IACS - 58% IACS, 58% IACS - 59% IACS, 59% IACS - 60% IACS, 60% IACS - 61% IACS, 61% IACS - 62% IACS, 62% IACS - 63% IACS, 63% IACS - 64% IACS, 64% IACS - 65% IACS.

[0011] In some embodiments, methods such as methods for fabricating battery components from recycled aluminum-containing alloys are described herein. Exemplary methods of this embodiment include providing a current collector comprising a recycled aluminum-containing alloy, subjecting the surface of the current collector to a coating process to produce a coating layer on at least a portion of the surface of the current collector. In some examples, the method further includes subjecting the current collector or the coating layer to a further coating process to form a conductive layer. The conductive layer may include one or more of a carbon-based material or a binder. In any example, the coating process may include a dip 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 evaporation, plasma spray physical vapor deposition, vacuum plasma spraying, metal gun spray deposition, plasma spraying, plasma transferred wire arc spraying, cold spraying, electrochemical vapor deposition, chemical vapor deposition, sputtering, dip coating, or any combination thereof.

[0012] The current collector fabricated by the method of this embodiment may include any of the current collectors described herein.

[0013] Other objectives and advantages will become apparent from the following detailed description of non-limiting examples.

[0014] This specification refers to the following accompanying drawings, and when the same reference numerals are used in different drawings, it is intended to indicate the same or similar components.

Brief Description of the Drawings

[0015]

Figure 1

Figure 2

Figure 3

DETAILED DESCRIPTION OF THE INVENTION

[0016] In this specification, battery components such as current collectors including recycled-content aluminum alloys are described, optionally with a coating layer disposed on at least a portion of the surface of the current collector. In various examples, the aluminum alloys used in the methods and products described herein include, for example, 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, or 7xxx series aluminum alloys.

[0017] With respect to 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 positive electrode side. However, using a current collector made from a recycled-content aluminum alloy can be more sustainable than using a relatively pure aluminum alloy. In some examples, depending on the non-aluminum materials present in the recycled-content aluminum alloy, the current collector made from the recycled-content aluminum alloy can have improved stability, conductivity, and lifespan. In other examples, using a recycled-content aluminum alloy as the current collector can result in a decrease in properties such as stability and conductivity.

[0018] For example, the recycled aluminum alloy-containing product may have a conductivity of 30% to 50% of the conductivity of a relatively pure aluminum alloy such as an aluminum alloy containing 99.99% or more Al. In some cases, the use of a recycled aluminum alloy-containing product that may reduce conductivity may go against the conventional teachings where high conductivity is desired, by improving the sustainability of aluminum products. Further, the coating layer can be disposed on the current collector to prevent non-aluminum elements in the recycled aluminum alloy-containing product from contacting lithium in the lithium-ion battery. The coating layer may prevent or limit corrosion and degradation of the current collector, and improve the stability and conductivity of the current collector.

[0019] Definitions and Explanations As used herein, the terms "invention", "the invention", "this invention", and "the present invention" are intended to broadly refer to all of the subject matter of this patent application and the following claims. It should be understood that descriptions containing these terms do not limit the subject matter described herein or the meaning or scope of the following claims.

[0020] In this description, reference is made to alloys identified by AA numbers and other related symbols (e.g., "series" or "7xxx"). For an understanding of the numbering systems most commonly used for the naming and identification of aluminum and its alloys, refer to "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).

[0021] As used herein, a plate generally has a thickness greater than about 15 mm. For example, a plate can 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.

[0022] As used herein, a sheet (also referred to as sheet plate) generally has a thickness of about 4 mm to about 15 mm. For example, a sheet can have a thickness of 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.

[0023] As used herein, a sheet refers generally to an aluminum product having a thickness less than about 4 mm. For example, a sheet can have a thickness 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).

[0024] In this application, reference may be made to alloy temper or alloy condition. To understand the most commonly used alloy temper descriptions, refer to "American National Standards (ANSI) H35 on Alloy and Temper Designation Systems". The F condition or temper refers to an as-fabricated aluminum alloy. The O condition or temper refers to an aluminum alloy after annealing. The Hxx condition or temper (also referred to herein as the H temper) refers to a non-heat-treated aluminum alloy after cold rolling, with or without heat treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8, or HX9 tempers. The T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). The T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked, and naturally aged. The T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. The T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. The T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at an elevated temperature). The T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. The T7 condition or temper refers to an aluminum alloy solution heat treated and over-aged. The T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. The T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. The W condition or temper refers to an aluminum alloy after solution heat treatment.

[0025] As used herein, terms such as "cast metal product", "cast product", "cast aluminum alloy product" are interchangeable and refer to products manufactured as products by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a double-belt casting machine, a double-roll casting machine, a block casting machine, or any other continuous casting machine), electromagnetic casting, hot top casting, or any other casting method.

[0026] As used herein, "room temperature" can mean a temperature of from about 15°C to about 30°C, for example, 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" can mean a temperature of approximately room temperature, a relative humidity of from about 20% to about 100%, and an atmospheric pressure of from 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%, or any value therebetween. For example, the atmospheric pressure can 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.

[0027] All ranges disclosed in this specification are to be understood to include any sub-ranges subsumed therein. For example, the recited range “1 to 10” should be considered to include any and all sub-ranges between the minimum value 1 and the maximum value 10 (including these values). That is, all sub-ranges start with a minimum value of 1 or more (e.g., 1 to 6.1) and end with a maximum value of 10 or less (e.g., 5.5 to 10). Unless otherwise stated, the term “maximum” when referring to the compositional amount of an element means that the element is optional and includes a zero percent composition of that particular element. Unless otherwise stated, all composition percentages are in weight percent (wt.%).

[0028] As used herein, the meanings of “a,” “an,” and “the” include references to both the singular and plural forms unless the context clearly dictates otherwise.

[0029] In the following examples, aluminum alloy products and their components may be described in terms of weight percent (wt.%) with respect to their elemental composition. In each alloy, if the total maximum wt.% of all impurities is 0.15%, the balance is aluminum.

[0030] Accompanying elements (e.g., grain refiners and deoxidizers), or other additives, may be present in the present invention and may add other properties by themselves without departing from or significantly changing the alloys described herein or the properties of the alloys described herein.

[0031] Inevitable impurities (including materials or elements) may be present in small amounts in the alloys due to the inherent properties of aluminum or elution due to contact with processing equipment. As described, some alloys may contain any element up to about 0.25 wt.% in addition to alloying elements, accompanying elements, and inevitable impurities.

[0032] Methods for manufacturing alloys and aluminum alloy products FIG. 1 provides a schematic overview of an exemplary method for fabricating a recycled-content aluminum alloy product. The method of FIG. 1 begins at step 105, where aluminum alloy 106 is cast to create a cast aluminum alloy product 107 such as an ingot or other cast product. At step 110, the cast aluminum alloy product 107 is homogenized to produce a homogenized aluminum alloy product 111. At step 115, the homogenized aluminum alloy product 111 is 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, sheet, or strip. Optionally, the rolled aluminum alloy product 112 may be subjected to one or more forming or stamping processes to form an aluminum alloy article.

[0033] The recycled-content alloys described herein can be cast using any suitable casting method known to those skilled in the art. As some non-limiting examples, the casting process may include a vertical semi-continuous (DC) casting process, a fusion casting process, or a continuous casting (CC) process. A continuous casting system may include a pair of movable opposing casting surfaces (e.g., movable opposing belts, rolls, or blocks), a casting cavity between the pair of movable opposing casting surfaces, and a molten metal injector. The molten metal injector may have an end opening through which molten metal exits the molten metal injector and can be injected into the casting cavity.

[0034] The cladding layer can be attached to the core layer by any means known to those skilled in the art to form a clad product. For example, the cladding layer can be attached to the core layer by direct chill simultaneous casting (i.e., fusion casting 115) as described, for example, in U.S. Pat. Nos. 7,748,434 and 8,927,113 (both of which are incorporated herein by reference in their entirety), by hot rolling and cold rolling a composite cast ingot as described in U.S. Pat. No. 7,472,740 (incorporated herein by reference in its entirety), or by roll bonding to achieve a metallurgical bond between the core and the cladding. The initial and final dimensions of the clad aluminum alloy product can be determined by the desired properties of the overall final product.

[0035] The roll bonding process can be carried out in different ways. For example, the roll bonding process can include both hot rolling and cold rolling. Further, the roll bonding process can be a one-step process or a multi-step process in which the material is reduced in gauge during successive rolling steps. The separate rolling steps can be optionally separated by other processing steps including, for example, annealing steps, cleaning steps, heating steps, cooling steps, etc.

[0036] Cast ingots, cast slabs, or other cast products can 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.

[0037] In the homogenization step, the cast product is heated to a temperature in the range of about 400°C to about 560°C. For example, the cast product can 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 500°C, about 510°C, about 520°C, about 530°C, about 540°C, about 550°C, or about 560°C. In some examples, the homogenization is performed at a temperature within 50°C of the solidus temperature of the cast product or its alloy. Next, the product is soaked (i.e., held at the indicated temperature) for a predetermined period to form a homogenized product. In some examples, the total time for the homogenization step (including the heating and soaking stages) can be up to 24 hours. For example, the product can be heated to a maximum of 500°C and soaked for a total time of up to 18 hours for the homogenization step. Optionally, the product can be heated to less than 490°C and soaked for a total time exceeding 18 hours for the homogenization step. 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 over a first period and then heating to a second temperature over a second period. For example, the cast product can be heated to about 465°C over about 3.5 hours and then heated to about 480°C over about 6 hours.

[0038] Following the homogenization step, a hot rolling step can be performed. Before starting hot rolling, the homogenized product may be allowed to cool to a temperature of 300°C to 450°C. For example, the homogenized product may be allowed to cool to a temperature of 325°C to 425°C or 350°C to 400°C. Next, the homogenized product is hot rolled at a temperature of 300°C to 450°C to form a hot rolled plate, hot rolled sheet, or hot rolled strip having a gauge of 3 mm to 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).

[0039] Optionally, the cast product can be a continuous cast product that can be cooled to a temperature of 300°C to 450°C. For example, the continuous cast product can be cooled to a temperature of 325°C to 425°C or 350°C to 400°C. Next, the continuous cast product is hot rolled at a temperature of 300°C to 450°C to form a hot rolled plate, hot rolled sheet, or hot rolled strip having a gauge of 3 mm to 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, the temperature and other operating parameters are controlled so that the temperature of the hot rolled intermediate product exiting the hot rolling mill can be 470°C or less, 450°C or less, 440°C or less, or 430°C or less.

[0040] Cast, homogenized, or hot-rolled products can optionally be cold-rolled using a cold rolling mill to produce thinner products (e.g., cold-rolled sheets). The cold-rolled products can have a gauge of about 0.5 to 10 mm, e.g., about 0.7 to 6.5 mm. Optionally, the cold-rolled products can have a gauge of 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 is performed to produce a final gauge thickness representing a maximum gauge reduction of 85% (e.g., a maximum reduction of 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 85%) compared to the gauge before starting cold rolling. Optionally, an intermediate annealing step can be performed during the cold rolling step. For example, a first cold rolling process is applied, followed by an annealing process (intermediate annealing), followed by a second cold rolling process. The intermediate annealing step can be performed at a temperature of about 300°C to about 450°C (e.g., about 310°C, 320°C, 330°C, 340°C, 350°C, 360°C, 370°C, 380°C, 390°C, 400°C, 410°C, 420°C, 430°C, 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 a partially cold-rolled product to a first temperature over a first period, followed by heating to a second temperature over a second period. For example, a partially cold-rolled product can be heated to about 410°C over about 1 hour and then to about 330°C over about 2 hours.

[0041] Thereafter, the cast, homogenized, or rolled product can optionally undergo a solution heat treatment step. The solution heat treatment step can be any suitable treatment for the sheet and results in the solid solution of soluble particles. The cast, homogenized, or rolled product can be heated to a peak metal temperature (PMT) of up to 590 °C (e.g., 400 °C to 590 °C) and held isothermally at the PMT for a certain period to form a high-temperature product. For example, the cast, homogenized, or rolled product can be held isothermally at 480 °C for a soaking time of 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). After heating and soaking, the high-temperature product is quenched to a temperature of 500 to 200 °C at a rate exceeding 200 °C / s to form a heat-treated product. In one example, the high-temperature product is cooled to a temperature of 450 °C to 200 °C at a quenching rate exceeding 200 °C per second. Optionally, in another case, the cooling rate can be made faster.

[0042] After quenching, the heat-treated product can optionally undergo an artificial aging treatment by reheating before cooling. The artificial aging treatment can be carried out at a temperature of about 70 °C to about 125 °C for a certain period of up to 6 hours. For example, the artificial aging treatment can be carried out 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 artificial aging treatment can be carried out for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. The artificial aging treatment can be performed by passing the heat-treated product through a heating device such as a device that generates radiant heat, convective heat, induction heat, infrared heat, etc.

[0043] Using the cast products described herein, products in the form of sheets, plates, or other suitable products can be fabricated. For example, a plate comprising the products described herein can be prepared by processing an ingot in a homogenization step or by casting the product in a continuous casting machine followed by a hot rolling step. In the hot rolling step, the cast product can be hot rolled to a gauge of 200 mm thickness or less (e.g., about 10 mm to about 200 mm). For example, the cast product can be hot rolled into plates with a final gauge thickness of 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 thinner metal products, sheets, etc.

[0044] In some examples, the rolled aluminum alloy product 112 can be provided or prepared for use as a current collector. The surface of the current collector can be subjected to a coating process to produce a coating layer on at least a portion of the surface of the current collector. The coating process can be a metal coating process that modifies one or more properties of the current collector. The properties can include the surface area of the current collector, the surface roughness of the current collector, the surface oxide layer, the electrical conductivity, the thermal conductivity, the corrosion resistance, the chemical reactivity, the electrolyte reactivity, the active material reactivity, the wetting characteristics, or the adhesion characteristics.

[0045] In any example, the current collector or the produced coating layer can be subjected to a further coating process to form a conductive layer. The conductive layer can include one or more of a carbon-based material or a binder. Examples of carbon-based materials can include carbon black materials or ketjen black materials. In some examples, the coating process can be a dip coating process or a roll-to-roll coating process.

[0046] In any example, the current collector and the coating layer can be subjected to a further coating step capable of forming an electrode active material layer on the coating layer. In any example, the coating process can be plasma-assisted physical vapor deposition, plasma-activated physical vacuum evaporation, plasma spray physical vapor deposition, vacuum plasma spraying, metal gun spray evaporation, plasma spraying, plasma transferred wire arc spraying, low-temperature spraying, electrochemical vapor deposition, chemical vapor deposition, sputtering, dip coating, dip coating process, roll-to-roll coating process, or any combination thereof.

[0047] Metal alloy In some examples, the metals used in the methods and products described herein include aluminum alloys, such as 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, or 7xxx series aluminum alloys. In some examples, the materials used in the methods and products described herein include non-ferrous materials, such as aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composite materials, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composite materials, sheets used in composite materials, or any other suitable combination of metals, non-metals, or materials. Monolithic, as well as non-monolithic, such as roll-bonded materials, clad alloys, clad layers, composite materials (e.g., but not limited to, carbon fiber-containing materials), or various other materials are also useful in the methods and products described herein. In some examples, aluminum alloys containing iron are useful in the methods and products described herein.

[0048] Non-limiting examples of 2xxx series alloys for use in the methods and products described herein include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

[0049] Non-limiting examples of 3xxx series 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, 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.

[0050] 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.

[0051] 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, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, 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, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

[0052] 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, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, 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.

[0053] 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, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0054] Battery components The recycled-content aluminum alloy products such as foils or sheets described in this specification can be used to fabricate battery components such as electronic substrates, which may be suitable for use as current collectors or in applications as devices (electrodes, electrochemical cells, or capacitors etc.) incorporating such current collectors. In any of the examples, the recycled-content aluminum alloy can be provided as a sheet or foil, but generally, in this specification, it is referred to as a layer in the context of a current collector. When used as a current collector, the recycled-content aluminum alloy layer can be coated with a coating layer or otherwise brought into contact, and the coating layer may also be referred to as a protective layer or a conductive protective layer in this specification. The recycled-content aluminum alloy can alternatively be provided as a coating on top of a coating layer that may optionally include a metal or metal alloy foil. In some cases, both the recycled-content aluminum alloy and the coating layer can include foils.

[0055] FIG. 2 provides a schematic cross-sectional view of an exemplary current collector 200 that includes a recycled-content aluminum alloy 205 and a coating layer 210 disposed on a surface of the recycled-content aluminum alloy 205. In the current collector 200, the coating layer 210 is shown in contact with only one surface or side of the recycled-content aluminum alloy 205; however, other configurations may be used, such as, for example, the coating layer 210 contacting different edges, surfaces, or faces of the recycled-content aluminum alloy 205. In any example, the current collector 200 may have a thickness of 0.005 mm to 0.5 mm. For example, the current collector 200 may have a thickness of 0.005 mm to 0.5 mm, such as, for example, 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, 0.225 mm to 0.25, 0.25 mm to 0.275 mm, 0.275 mm to 0.3 mm, 0.3 mm to 0.325 mm, 0.325 mm to 0.35 mm, 0.35 mm to 0.375 mm, 0.375 mm to 0.4 mm, 0.4 mm to 0.425 mm, 0.425 mm to 0.45 mm, 0.45 mm to 0.475 mm, or 0.475 mm to 0.5 mm.

[0056] In any example, the recycled aluminum alloy 205 can contain a recycled aluminum content of 50% to 100%. For example, the recycled aluminum alloy 205 can contain a recycled aluminum content of 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100%.

[0057] In any example, the recycled aluminum alloy 205 may contain 50 wt.% to 99.999 wt.% of aluminum (Al). For example, the recycled aluminum alloy 205 may contain 50 wt.% to 60 wt.% of Al. For example, 50 wt.% to 60 wt.% of Al, 50 wt.% to 70 wt.% of Al, 50 wt.% to 80 wt.% of Al, 50 wt.% to 90 wt.% of Al, 50 wt.% to 99.999 wt.% of Al, 60 wt.% to 70 wt.% of Al, 60 wt.% to 80 wt.% of Al, 60 wt.% to 90 wt.% of Al, 60 wt.% to 99.999 wt.% of Al, 70 wt.% to 80 wt.% of Al, 70 wt.% to 90 wt.% of Al, 70 wt.% to 99.999 wt.% of Al, 80 wt.% to 90 wt.% of Al, 80 wt.% to 99.999 wt.% of Al, or 90 wt.% to 99.999 wt.% of Al can be mentioned.

[0058] In some cases, the recycled aluminum alloy 205 may be a 3xxx series aluminum alloy or a 5xxx series aluminum alloy. In other cases, the recycled 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 aluminum alloy 205 may not include a 1xxx series aluminum alloy or an 8xxx series aluminum alloy.

[0059] The coating layer 210 may be useful for preventing the material from directly contacting the recycled aluminum alloy 205 in applications such as the current collector 200 for a battery. In some examples, the coating layer 210 may function to block the permeation of a specific material or prevent it in other ways, such as restricting the contact between a specific material and the underlying recycled aluminum alloy 205. Optionally, the coating layer 210 may be conductive and may allow electrons to pass through the recycled aluminum alloy. In some examples, the coating layer 210 may be a carbon-based material. Examples of carbon-based materials may include carbon black materials or ketjen black materials.

[0060] The coating layer 210 can have any suitable thickness. Exemplary thicknesses can be from 5 nm to 100 μm, such as, for example, 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, 900 nm 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.

[0061] Some exemplary techniques for creating the coating layer 210 can include, but are not limited to, physical deposition processes, sputter deposition processes, evaporation processes, chemical deposition processes, electrodeposition processes, electroplating processes, chemical vapor deposition processes, or atomic layer deposition processes.

[0062] In some cases, it may be desirable to achieve partial or complete encapsulation of the recycled-containing aluminum alloy 205 by the coating layer 210. For example, the coating layer 210 can partially coat the surface or can completely coat the surface. Such a configuration can be achieved, for example, by using a non-directional deposition technique such as an electrodeposition process, which is a solution-phase process and can result in complete coating or encapsulation of the recycled-containing aluminum alloy 205 by the coating layer 210. In some cases, the coating layer 210 can be a multi-layer coating. Each layer of the multi-layer coating can have the same or a different composition from the other layers.

[0063] The coating layer 210 can be formed on the recycled aluminum alloy 205 by a metal coating process that modifies one or more properties of the recycled aluminum alloy 205 containing recycled materials. The one or more characteristics may include the surface area of the recycled aluminum alloy 205 containing recycled materials, the surface roughness of the recycled aluminum alloy 205 containing recycled materials, the oxide layer on the surface, conductivity, thermal conductivity, corrosion resistance, reactivity of the active material, wetting characteristics, or adhesion characteristics. It may be beneficial for the coating layer 210 or the current collector 200 to have a conductivity of 30% IACS to 65% IACS as a whole. For example, the current collector 200 may have an electrical conductivity of 30% IACS to 65% IACS, such as 30% to 31% IACS, 31% IACS to 32% IACS, 33% IACS to 34% IACS, 34% IACS to 35% IACS, 35% IACS to 36% IACS, 36% IACS to 37% IACS, 37% IACS to 38% IACS, 38% IACS to 39% IACS, 40% IACS to 41% IACS, 41% IACS to 42% IACS, 42% IACS to 43% IACS, 43% IACS to 44% IACS, 44% IACS to 45% IACS, 45% IACS to 46% IACS, 46% IACS to 47% IACS, 47% IACS to 48% IACS, 48% IACS to 49% IACS, 49% IACS to 50% IACS, 50% 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, etc.

[0064] Method of using the disclosed product made of recycled aluminum alloy containing recycled materials The recycled-content aluminum alloy products described in this specification can be used in electronic device applications. For example, the aluminum alloy products and methods described in this specification can be used to process housings for electronic devices (including mobile phones and tablet computers). In some examples, the recycled-content aluminum alloy products can be used to process current collectors and electrodes used in electrochemical cells, capacitors, or batteries that can be used in mobile phones, tablet computers, and the like.

[0065] FIG. 3 provides a schematic cross-sectional view of an exemplary current collector that includes a recycled-content aluminum alloy 305 within a lithium-ion battery 300. The lithium-ion battery 300 includes a first electrode 302 that can correspond to a cathode in some examples, and a second electrode 304 that can 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 can include a recycled-content aluminum alloy. The first electrode 302 also includes a first active material 330, such as a positive electrode 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 layer 310. The second electrode 304 also includes a second active material 315, such as a negative electrode active material. For the lithium-ion battery 300 shown in FIG. 3, the current collector 320 is not coated and the current collector 306 includes the coating 310, and has been described above with reference thereto, but such a configuration is not intended to be limiting, and one or both of the current collector 320 and the current collector 306 can include a coating layer or can exclude a coating layer.

[0066] The lithium-ion battery 300 also includes a separator and / or an electrolyte, shown as component 335. The separator and / or electrolyte is useful for preventing the first and second electrode active materials from contacting each other while allowing ions to be transported during charging or discharging. Exemplary separators can be, or include, non-reactive porous materials such as polymer membranes like polypropylene, poly(methyl methacrylate), or polyacrylonitrile. Exemplary electrolytes can be, or include, organic solvents such as ethylene carbonate, dimethyl carbonate, or diethyl carbonate, or solid electrolytes or ceramic electrolytes. The electrolyte can include dissolved lithium salts such as LiPF6, LiBF4, or LiClO4, and other additives.

[0067] The examples disclosed herein serve to further illustrate aspects of the present invention, but at the same time, do not constitute any limitation thereof. On the contrary, it should be clearly understood that various embodiments, modifications thereof, and equivalents may have to be relied upon. These can suggest themselves to those skilled in the art after reading the description herein, without departing from the spirit of the present invention. Also, the examples and embodiments described herein may utilize conventional procedures, unless otherwise specified. Some of the procedures are described herein for illustrative purposes.

[0068] Exemplary aspects As used below, any reference to a series of aspects (e.g., "Aspects 1-4") or an unenumerated set of aspects is to be understood as referring to each of those groups discretely (e.g., "Aspects 1-4" is to be understood as "Aspects 1, 2, 3, or 4").

[0069] Aspect 1 is a battery component including a current collector including a recycled-containing aluminum alloy and a coating layer disposed on at least a portion of the surface of the current collector.

[0070] Aspect 2 is the battery component according to any of the preceding or subsequent aspects, wherein the current collector contains 50% to 100% recycled aluminum content.

[0071] Aspect 3 is the battery component according to any of the preceding or subsequent aspects, wherein the current collector contains an aluminum alloy of the 3xxx series or an aluminum alloy of the 5xxx series.

[0072] Aspect 4 is the battery component according to any of the preceding or subsequent aspects, wherein the current collector has a thickness of 0.005 mm to 0.5 mm.

[0073] Aspect 5 is the battery component according to any of the preceding or subsequent aspects, wherein the current collector does not contain an aluminum alloy of the 1xxx series or an aluminum alloy of the 8xxx series.

[0074] Aspect 6 is the battery component according to any of the preceding or subsequent aspects, wherein the aluminum alloy contains an aluminum alloy of the 2xxx series, an aluminum alloy of the 4xxx series, an aluminum alloy of the 6xxx series, or an aluminum alloy of the 7xxx series.

[0075] Aspect 7 is the battery component according to any of the preceding or subsequent aspects, wherein the current collector contains 50 wt.% to 99.9 wt.% Al.

[0076] Aspect 8 is the battery component according to any of the preceding or subsequent aspects, wherein the current collector contains 80 wt.% to 99 wt.% Al.

[0077] Aspect 9 is the battery component according to any of the preceding or subsequent aspects, wherein the coating layer contains a carbon-based material.

[0078] Aspect 10 is the battery component according to any of the preceding or subsequent aspects, wherein the carbon-based material contains a carbon black material or a ketjen black material.

[0079] Aspect 11 is the battery component according to any of the preceding or subsequent aspects, wherein the coating layer has a thickness of 5 nm to 100 μm.

[0080] Aspect 12 is the battery component according to any of the preceding or subsequent aspects, wherein the coating layer completely coats the surface of the current collector or the coating layer partially coats the surface of the current collector.

[0081] Aspect 13 is the battery component according to any of the preceding or subsequent aspects, wherein the coating layer includes a multilayer coating.

[0082] Aspect 14 is the battery component according to any of the preceding or subsequent aspects, wherein one or more characteristics of the current collector are modified by a metal coating process to form the coating layer on at least a part of the surface of the current collector, and the one or more characteristics of the current collector include the surface area of the current collector, the surface roughness of the current collector, the surface oxide layer, the electrical conductivity, the thermal conductivity, the corrosion resistance, the chemical reactivity, the electrolyte reactivity, the active material reactivity, the wetting characteristics, or the adhesion characteristics.

[0083] Aspect 15 is the battery component according to any of the preceding or subsequent aspects, wherein the conductivity of the current collector is 30% IACS to 65% IACS.

[0084] Aspect 16 is a method of manufacturing a battery component, the method including providing a current collector including a recycled-containing aluminum alloy, and providing the surface of the current collector to a coating process to form a coating layer on at least a part of the surface of the current collector.

[0085] Aspect 17 is the method according to any of the preceding or subsequent aspects, wherein the coating process modifies one or more properties of the current collector, such as surface properties.

[0086] Aspect 18 is the method according to any of the preceding or subsequent aspects, wherein the one or more features of the current collector 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 characteristics, or adhesion characteristics.

[0087] Aspect 19 is the method according to any of the preceding or subsequent aspects, wherein the current collector or the coating layer is subjected to a further coating process for forming a conductive layer, and the conductive layer includes one or more of a carbon-based material or a binder.

[0088] Aspect 20 is the method according to any of the preceding or subsequent aspects, wherein the coating process includes a dip coating process or a roll-to-roll coating process.

[0089] Aspect 21 is the method according to any of the preceding or subsequent aspects, further including providing the current collector and the coating layer to a further coating process and forming an electrode active material layer on the coating layer.

[0090] Aspect 22 is the method according to any of the preceding or subsequent aspects, wherein the coating process includes plasma-assisted physical vapor deposition, plasma-activated physical vacuum evaporation, plasma spray physical vapor deposition, vacuum plasma spraying, metal gun spray deposition, plasma spraying, plasma transferred wire arc spraying, low-temperature spraying, electrochemical vapor deposition, chemical vapor deposition, sputtering, dip coating, dip coating process, roll-to-roll coating process, or any combination thereof.

[0091] Aspect 23 is a method according to any of the preceding or subsequent aspects, wherein the battery component is a battery component of any of the preceding aspects.

[0092] Aspect 24 is a battery component according to any of the preceding or subsequent aspects, wherein the battery component is prepared according to a method of any of the preceding aspects.

[0093] Aspect 25 is a battery comprising a battery component according to any of the preceding or subsequent aspects.

[0094] Aspect 26 is a battery comprising a battery component according to any of the preceding or subsequent aspects, the battery comprising a negative electrode active material, a positive electrode active material, and an electrolyte between the negative electrode active material and the positive electrode active material, wherein the battery component is a current collector in electrical contact with the negative electrode active material or the positive electrode active material.

[0095] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of embodiments including the illustrated embodiments is presented for purposes of illustration and description only and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

1. A battery component, comprising: a current collector containing recycled aluminum alloy; a coating layer disposed on at least a part of the surface of the current collector; The battery component comprising the above.

2. The battery component according to Claim 1, wherein the current collector contains a recycled aluminum content of 50% to 100%.

3. The battery component according to Claim 1, wherein the current collector contains an aluminum alloy of the 3xxx series or an aluminum alloy of the 5xxx series.

4. 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 according to Claim 1, wherein the current collector does not contain an aluminum alloy of the 1xxx series or an aluminum alloy of the 8xxx series.

6. The method according to Claim 1, wherein the current collector contains an aluminum alloy of the 2xxx series, an aluminum alloy of the 4xxx series, an aluminum alloy of the 6xxx series, or an aluminum alloy of the 7xxx series.

7. The battery component according to Claim 1, wherein the current collector contains 50 wt.% to 99.9 wt.% of Al.

8. The battery component according to Claim 1, wherein the current collector contains 80 wt.% to 99 wt.% of Al.

9. The battery component according to Claim 1, wherein the coating layer contains a carbon-based material.

10. The battery component according to Claim 9, wherein the carbon-based material contains 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 according to Claim 1, wherein the coating layer completely coats the surface of the current collector, or the coating layer partially coats the surface of the current collector.

13. The battery component according to Claim 1, wherein the coating layer contains a multilayer coating.

14. One or more features of the current collector are modified by a metal coating process to produce the coating layer on at least a portion of the surface of the current collector, and the one or more features of the current collector 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 characteristics, or adhesion characteristics. The battery component according to claim 1.

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

16. A method of manufacturing a battery component, providing a current collector, the current collector comprising a recycled-containing aluminum alloy, subjecting the surface of the current collector to a coating process to produce a coating layer on at least a portion of the surface of the current collector, the method comprising the above.

17. The method according to claim 16, wherein the coating process modifies one or more surface characteristics of the current collector.

18. The one or more features of the current collector 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 characteristics, or adhesion characteristics, according to the method of claim 17.

19. The method according to claim 16, further comprising subjecting the current collector or the coating layer to a further coating process to form a conductive layer, the conductive layer including one or more of a carbon-based material or a binder.

20. The method according to claim 19, wherein the coating process includes a dip coating process or a roll-to-roll coating process.

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

22. The coating process is the method according to claim 16, including plasma-assisted physical vapor deposition, plasma-activated physical vacuum evaporation, plasma spray physical vapor deposition, vacuum plasma spraying, metal gun spray evaporation, plasma spraying, plasma transferred wire arc spraying, low-temperature spraying, electrochemical deposition, chemical vapor deposition, sputtering, dip coating, dip coating process, roll-to-roll coating process, or any combination thereof.

23. The method according to claim 16, wherein the battery component is the battery component according to 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. A negative electrode active material, A positive electrode active material, An electrolyte between the negative electrode active material and the positive electrode active material and the battery component is a current collector in electrical contact with the negative electrode active material or the positive electrode active material, The battery according to claim 25.

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