Electrode binder composition and method for manufacturing electrodes for secondary batteries

Abstract

The present invention provides a binder composition that can be used in a dry electrode mixture or electrode slurry for manufacturing electrodes, and a method for manufacturing electrodes for secondary batteries. [Solution] The binder composition comprises a water-compatible copolymer and has a liquid content of less than 85% by weight based on the total weight of the binder composition. The reduced liquid content of the binder composition improves transport and storage efficiency compared to conventional wet binder compositions. The binder composition disclosed herein has a wide range of applications and can be successfully used in dry electrode mixtures and electrode slurries. A battery containing electrodes prepared using the binder composition disclosed herein has electrochemical performance comparable to a battery containing electrodes manufactured via a conventional wet binder composition.

Description

[Technical Field]

[0001] This invention relates to the field of batteries. In particular, this invention relates to a binder composition that can be used in electrode slurries and dried electrode mixtures of lithium-ion batteries and other metal-ion batteries. Background of the Invention

[0002] Over the past several decades, lithium-ion batteries (LIBs) have become widely used in a variety of applications, particularly in consumer electronics, due to their superior energy density, long cycle life, and high discharge capacity. With the rapid market development of electric vehicles (EVs) and grid energy storage, high-performance, low-cost LIBs are now one of the most promising options for large-scale energy storage devices.

[0003] Generally, the electrodes of lithium-ion batteries consist of an electrode active material, conductive carbon, and a binder composition. The binder composition provides good electrochemical stability to the electrode layer, binds the electrode layer materials together, and adheres the electrode layer materials to the current collector. For electrode formation, a slurry is often used in which the various components of the electrode are suspended or dissolved in a solvent to facilitate processing and coating. Polyvinylidene fluoride (PVDF) is one of the most commonly used binder polymers in the commercially available lithium-ion battery industry. While it functions as a binder composition itself, PVDF can only be dissolved in certain organic solvents, such as N-methyl-2-pyrrolidone (NMP). Therefore, these organic solvents are used as solvents for electrode slurries made of PVDF. However, NMP is flammable and toxic, so care must be taken when handling it. Furthermore, an NMP recovery device must be installed in the drying process to recover NMP vapor. This necessitates a large capital investment and incurs significant costs in the manufacturing process.

[0004] Considering the drawbacks of forming electrodes using organic solvent slurries, the use of aqueous solvents, most commonly water, as a substitute is being considered. Since PVDF is insoluble in water and has poor dispersibility, a binder polymer that is compatible with water is used instead of PVDF in aqueous electrode slurries. Conventional methods for producing the aforementioned polymer require a large amount of aqueous solvent in the polymerization step, making it easiest to produce a binder composition consisting of the polymer and a large amount of aqueous solvent.

[0005] When scaled up to an industrial scale, the large amount of aqueous solvent present in the binder composition presents storage problems, as even moderate amounts of the binder composition require a significant amount of storage space. Furthermore, in industrial settings, the manufacture of the binder composition and the manufacture of the electrodes do not necessarily take place in the same location, and the finished binder composition may need to be transported to a different facility for electrode manufacturing. In such cases, the high liquid content also makes it difficult to move the binder composition from one facility to another. Clearly, the presence of a large amount of aqueous solvent in the binder composition will pose a significant logistical challenge to the efficient manufacture of electrodes.

[0006] U.S. Patent No. 10,741,843 discloses an electrode layer manufacturing process in which an electrode active material, conductive carbon, and dry PVDF as a binder composition are mixed, and then calendered directly onto a current collector without the addition of a solvent. In other words, a dry electrode mixture is used to manufacture the electrode layer, and it is essential to use PVDF, which is a water-insoluble polymer. Since PVDF does not mix with water, it is readily available in a dry state, making it easy to prepare the dry electrode mixture. For this reason, PVDF is particularly suitable for manufacturing dry electrode mixtures, which explains why dry PVDF was selected to manufacture the dry electrode layer in the aforementioned patent document.

[0007] On the other hand, water-compatible polymers are not readily available in a dry state. Some water-compatible polymers undergo irreversible morphological changes after drying, making it more difficult to separate and dry them to form a substantially liquid-free binder composition. That is, even if moisture is added, such polymers may not return to their pre-drying form, resulting in a permanent deterioration of their binder performance once dried. Furthermore, some binder compositions made of water-soluble polymers have a high affinity for aqueous solvents and are not easily separated, making it difficult even to reduce the liquid content of the binder composition without completely drying it. [Overview of the project]

[0008] Therefore, as a result of diligent research, the present inventors have found that a water-compatible binder composition with reduced liquid content (to the extent that virtually no liquid remains) can be easily produced by processing a wet binder composition containing the water-soluble copolymer and aqueous solvent disclosed herein. A battery containing electrodes produced using the binder composition disclosed herein has electrochemical performance equivalent to that of a battery containing electrodes produced using a conventional wet binder composition. Accordingly, the object of the present invention is to present a binder composition with reduced liquid content that contains a water-compatible copolymer and can maintain binder performance equivalent to that of a conventional wet binder composition. [Brief explanation of the drawing]

[0009] [Figure 1] This flowchart provides an overview of the various embodiments disclosed herein. [Modes for carrying out the invention]

[0010] The aforementioned needs are met by the various aspects and embodiments disclosed herein. In one aspect, provided herein is a binder composition that can be used in a dry electrode mixture or electrode slurry to manufacture an electrode, wherein the binder composition comprises a water-compatible copolymer and has a liquid content of less than 85% by weight based on the total weight of the binder composition. In another aspect, various dry electrode mixtures and electrode slurries utilizing such a binder composition are disclosed. Despite having a reduced liquid content, the binder compositions disclosed herein can maintain binder performance comparable to conventional wet binder compositions. Furthermore, a battery containing electrodes manufactured using the binder compositions disclosed herein has electrochemical performance equivalent to that of a battery containing electrodes manufactured via a wet binder composition.

[0011] In one embodiment, the herein provides a binder composition that can be used in a dry electrode mixture or electrode slurry to manufacture an electrode, wherein the binder composition comprises a water-compatible copolymer and has a reduced liquid content compared to conventional wet binder compositions. In another embodiment, various dry electrode mixtures and electrode slurries utilizing such a binder composition are disclosed. In yet another embodiment, electrodes prepared using dry electrode mixtures and slurries are disclosed.

[0012] The term "electrode" refers to either a "positive electrode (cathode)" or a "negative electrode (anode)." In some embodiments, the electrode consists of a current collector and an electrode layer.

[0013] The term "positive electrode" is used interchangeably with "positive electrode." Similarly, the term "negative electrode" is used interchangeably with "negative electrode."

[0014] The term "current collector" refers to any conductive substrate that is in contact with the electrode layer and is capable of conducting the current flowing to the electrodes during the discharge or charge of a secondary battery. Non-limiting examples of current collectors include a single conductive metal layer or substrate, and a single conductive metal layer or substrate having a conductive coating layer on top of it, such as a carbon black-based coating layer. The conductive metal layer or substrate may be in the form of a foil or porous body having a three-dimensional network structure, and may be a polymer material, a metallic material, or a metallized polymer. In some embodiments, the three-dimensional porous current collector is covered with a conformal carbon layer.

[0015] The term "electrode layer" refers to a layer made of an electrochemically active material that is in contact with the current collector. In some embodiments, the electrode layer is created by applying a coating to the current collector. In some embodiments, the electrode layer is located on the surface of the current collector. In other embodiments, a three-dimensional porous current collector is conformally coated with an electrode layer.

[0016] The term "polymer" refers to high-molecular-weight compounds prepared by polymerizing monomers, whether of the same or different types. The general term "polymer" encompasses not only "homopolymers" but also "copolymers."

[0017] The term "homopolymer" refers to a polymer prepared by the polymerization of monomers of the same type.

[0018] The term "copolymer" refers to a polymer prepared by the polymerization of two or more different types of monomers. In some embodiments, copolymers are random copolymers, periodic copolymers, statistical copolymers, alternating copolymers, block copolymers, stereoblock copolymers, gradient copolymers, graft copolymers, star copolymers, brush copolymers, comb copolymers, or combinations thereof.

[0019] The term "water compatibility" in relation to chemical compounds, mixtures of compounds, or polymers refers to the ability of a chemical compound, mixture of compounds, or polymer to disperse well in water and form a solution or colloid.

[0020] The term “binder composition” refers to a chemical compound, mixture of compounds, or polymer used to hold materials in place and to adhere materials onto a substrate. In some embodiments, the binder composition is used to hold electrode components in place and to adhere them to conductive metal portions to form electrodes. In some embodiments, the binder composition consists of a polymer. Such polymers may be called “binder polymers.” In some embodiments, the binder composition contains a polymer that is a copolymer. Such copolymers may be called “binder copolymers.” In some embodiments, the binder composition contains a liquid, where the liquid is an aqueous solvent. In some embodiments, the binder composition is substantially liquid-free. In other embodiments, the binder composition contains no liquid.

[0021] In the context of mixtures, the term "dry" means that the mixture contains substantially no liquid or no liquid at all. The term "substantially liquid" in the context of mixtures means that the mixture has a very low liquid content. In a particular embodiment, “substantially liquid-free” means that the mixture has a liquid content of less than 1% by weight, less than 0.8% by weight, less than 0.6% by weight, less than 0.5% by weight, less than 0.4% by weight, less than 0.3% by weight, less than 0.2% by weight, less than 0.15% by weight, less than 0.1% by weight, less than 0.05% by weight, less than 0.03% by weight, less than 0.02% by weight, less than 0.015% by weight, less than 0.01% by weight, less than 0.075% by weight, less than 0.05% by weight, less than 0.025% by weight, less than 0.02% by weight, less than 0.015% by weight, less than 0.0075% by weight, less than 0.005% by weight, less than 0.0025% by weight, less than 0.002% by weight, less than 0.0015% by weight, or less than 0.001% by weight, based on the total weight of the mixture.

[0022] The term "conductive agent" refers to a material that possesses good electrical conductivity. Therefore, to improve the electrical conductivity of electrodes, conductive agents are often mixed with the electrode active material during electrode formation. In some embodiments, the conductive agent is chemically active. In some embodiments, the conductive agent is chemically inert.

[0023] The term “dry electrode mixture” refers to a mixture of materials that can be used to form an electrode layer, and such mixture of materials is substantially liquid-free or liquid-free. In some embodiments, the dry electrode mixture comprises an electrode active material and a binder composition. In some embodiments, the dry electrode mixture further comprises a conductive agent.

[0024] The term "electrode slurry" refers to a mixture of materials that can be used to form an electrode layer, the mixture containing a liquid solvent. In some embodiments, the electrode slurry comprises an electrode active material and a binder composition. In some embodiments, the electrode slurry further comprises a conductive agent.

[0025] The term "particle size D50" refers to the 50% volume cumulative size (D50), which is the particle size at the 50% point on the cumulative curve when the total volume is set to 100% (i.e., the diameter of the particle representing 50% (median) of the particle volume). Furthermore, with respect to the electrode active material of the present invention, particle size D50 refers to the volume-average particle size of secondary particles that can be formed by the aggregation of primary particles, and if it consists only of primary particles, it refers to the volume-average particle size of the primary particles.

[0026] As used herein, the term "unsaturated" means a site having one or more carbon-carbon double or triple bonds.

[0027] The term "alkyl" or "alkyl group" refers to the general formula C n H 2n+1The term refers to a monovalent group obtained by removing a hydrogen atom from a saturated, unbranched, or branched aliphatic hydrocarbon, where n is an integer. Examples of alkyl groups include, but are not limited to, methyl, ethyl, propyl, isopropyl, 2-methyl-1-propyl, 2-methyl-2-propyl, 2-methyl-1-butyl, 3-methyl-1-butyl, 2-methyl-3-butyl, 2,2-dimethyl-1-propyl, 2-methyl-1-pentyl, 3-methyl-1-pentyl, 4-methyl-1-pentyl, 2-methyl-2-pentyl, 3-methyl-2-pentyl, 4-methyl-2-pentyl, 2,2-dimethyl-1-butyl, 3,3-dimethyl-1-butyl, 2-ethyl-1-butyl, butyl, isobutyl, t-butyl, pentile, isopentyl, neopentyl, hexyl, heptyl, and octyl. Examples of long-chain alkyl groups include nonyl and decyl groups. The alkyl group may be unsubstituted or substituted with one or more suitable substituents. Furthermore, the alkyl group may be branched or unbranched.

[0028] The term "alkenyl" refers to a monovalent group obtained by removing a hydrogen atom from an unsaturated aliphatic hydrocarbon having at least one carbon-carbon double bond, which may or may not be branched. Non-limiting examples of alkenyls include vinyl, 1-propenyl, 2-propenyl, isobutenyl, and butadienyl. Similarly, the term "alkynyl" refers to a monovalent group obtained by removing a hydrogen atom from an unsaturated aliphatic hydrocarbon having at least one carbon-carbon triple bond, which may or may not be branched. Non-limiting examples of alkenyls include ethynyl, 3-methylpento-1-in-3-yl (HC≡CC(CH3)(C2H5)-), and butadinyl.

[0029] The term "alkylene" refers to a saturated divalent hydrocarbon group obtained by removing two hydrogen atoms from a straight-chain or branched-chain saturated hydrocarbon. Examples of alkylene groups include methylene (-CH2-), ethylene (-CH2CH2-), and isopropylene (-CH(CH3)CH2-). The alkylene group may be optionally substituted with one or more substituents as described herein.

[0030] The term "cycloalkyl" refers to a saturated or unsaturated cyclic non-aromatic hydrocarbon radical having a monocyclic or multiple fused rings. Examples of cycloalkyl groups include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl; cycloalkenyl groups such as cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclohexenyl, and cycloheptenyl; and cyclic and bicyclic terpenes. Cycloalkyl groups can be unsubstituted or substituted with one or two appropriate substituents.

[0031] The term "alkoxy" refers to an alkyl group bonded to the main carbon chain via an oxygen atom. Some non-exclusive examples of alkoxy groups include methoxy, ethoxy, propoxy, and butoxy. Alkoxy groups may be substituted or unsubstituted, and substituents may be, but are not limited to, deuterium, hydroxy, amino, halo, cyano, alkoxy, alkyl, alkenyl, alkynyl, mercapto, and nitro.

[0032] The term "aryl" or "aryl group" refers to an organic radical derived from monocyclic or polycyclic aromatic hydrocarbons by removing a hydrogen atom. Non-exclusive examples of aryl groups include phenyl, naphthyl, benzyl, tranyl, sexiphenyl, phenantrenyl, anthracenyl, coronenyl, and tranylphenyl. Aryl groups may be unsubstituted or substituted with one or more suitable substituents.

[0033] The term "aliphatic" refers to non-aromatic hydrocarbons or groups derived therefrom. Some non-exclusive examples of aliphatic compounds include alkanes, alkenes, alkynes, alkyls, alkenyls, alkynyls, alkylene groups, alkenylene groups, or alkynylene groups.

[0034] The term "aromatic" refers to a group consisting of an aromatic hydrocarbon ring, which may optionally contain heteroatoms or substituents. Examples of such groups include, but are not limited to, phenyl, tolyl, biphenyl, o-terphenyl, m-terphenyl, p-terphenyl, naphthyl, anthryl, phenanthuryl, pyrenyl, triphenyl, and their derivatives.

[0035] The term "substituted" refers to a compound or chemical site in which at least one hydrogen atom of the compound or chemical site is substituted by a second chemical site. This second chemical site is known as a "substituent." Examples of substituents include halogens; alkyls; heteroalkyls; alkenyls; alkynyls; aryls, heteroaryls, hydroxyls; alkoxyls; aminos; nitros; thiols; thioethers; imines; cyanos; amides; phosphonates; phosphinates; carboxyls; thiocarbonyls; sulfonyls; sulfonamides; acyls; formyls; acyloxys; alkoxycarbonyls; oxo; haloalkyls (e.g., trifluoromethyl); carbocyclic cycloalkyls that can be monocyclic or condensed or uncondensed polycyclic (e.g., cyclopropyl, cyclobutyl, cyclopentyl, or cyclohexyl); monocyclic... These may be heterocyclic compounds that can be condensed or uncondensed polycyclic (e.g., pyrrolidinyl, piperidinyl, piperazinyl, morpholinyl, or thiadinyl); monocyclic or condensed or uncondensed polycyclic aryls, which may be carbocyclic or heterocyclic (e.g., phenyl, naphthyl, pyrrolyl, indolyl, furanyl, thiophenyl, imidazolyl, oxazolyl, isoxazolyl, thiazolyl, triazolyl, tetrazolyl, pyrazolyl, pyridinyl, quinolinyl, isoquinolinyl, acridinyl, pyrazinyl, pyridadinyl, pyrimidinyl, benzimidazolyl, benzthiophenyl, or benzofuranyl). Amino (primary, secondary, or tertiary); o-lower alkyl; o-aryl, aryl, aryl lower alkyl; -CO2CH3; -CONH2; -OCH2CONH2; -NH2; -SO2NH2; -OCHF2; -CF3; -OCF3; -NH(alkyl); -N(alkyl)2; -NH(aryl); -N(alkyl)(aryl); -N(aryl)2; -CHO-CO(alkyl); CO(aryl); CO2(alkyl); and -CO2(aryl); and such moieties may also be optionally substituted by fused ring structures or bridges, e.g., -OCH2O-. These substituents may be further substituted with substituents optionally selected from such groups. All chemical groups disclosed herein may be substituted unless otherwise specified.

[0036] The term "halogen" refers to F, Cl, Br, or I.

[0037] The term "monomer unit" refers to a constituent unit that a single monomer contributes to the structure of a polymer.

[0038] The term "structural unit" refers to all monomer units in a polymer that are contributed by the same monomer type.

[0039] The polymer term "number-average molecular weight" (Mn) is mathematically defined as follows:

number

[0040] The polymer term "weight-average molecular weight" (Mw) is mathematically defined as follows:

number

[0041] In polymer terminology, the "polydispersity index" (PDI) refers to the ratio of the weight-average molecular weight to the number-average molecular weight (i.e., Mw / Mn) of a polymer. It is a measure of the molecular weight distribution within a given polymer sample.

[0042] The term “homogenizer” refers to a device that can be used to homogenize materials. “Homogenization” refers to the process of uniformly distributing a material throughout a mixture. Any conventional homogenizer can be used in the methods disclosed herein. Some non-limiting examples of homogenizers include stirring mixers, planetary mixers, tumblers, and mills.

[0043] The term "tumbler" refers to a device that can be used to mix or agitate different materials to produce a homogeneous mixture, the device consisting of a container that rotates around a fixed axis, and the container contains the material to be agitated. In some embodiments, the tumbler does not include an impeller. In some embodiments, the tumbler includes a freely moving component, such as a ball or pebble, to reduce particle aggregation. The rotational speed can be expressed in revolutions per minute (rpm), which refers to the number of rotations the rotating body completes in one minute.

[0044] The term "agitator / mixer" refers to a device that can be used to mix or agitate different materials to produce a homogeneous mixture, and consists of one or more impellers rotating around a fixed axis within a container. The term "planetary mixer" refers to a device that can be used to mix or agitate different materials to produce a homogeneous mixture, and the device consists of two or more impellers rotating on their own axes while rotating continuously within a container. In some embodiments, a planetary mixer includes at least one planetary blade and at least one high-speed dispersion blade as impellers. The rotational speed can be expressed in rpm.

[0045] The term "mill" refers to a device that reduces the particle size of a material, and this device includes mixers that can be used to mix or stir different materials to produce a homogeneous mixture. Particle size can be reduced by abrading particles using a variety of methods, including but not limited to the surface of a container, pressurized gas, or heavy spheres.

[0046] The term "coating" refers to the act of spreading or covering a surface with a substance.

[0047] The term "roll press" refers to a device that uses rollers to compress a powdered material into a uniform coating layer. In some embodiments, the rollers can compress the powder into a distinct layer and then press it onto a substrate. In some embodiments, the rollers compress the powder directly onto the substrate to form a coating layer.

[0048] The term "forming press" refers to a device that uses mechanical force to generate high pressure in order to form a coating layer or pellet from powder using one or more molds. In some embodiments, this force may be provided by pneumatic or hydraulic pistons. The term "tablet press" refers to a forming press that forms small pellets from powder.

[0049] "Transfer coating" refers to a process for forming a large-area film on a hard or soft substrate. Instead of directly applying the slurry to the substrate to form a coating layer, the slurry is first applied to a release film. Next, the release film with the coating layer is brought into contact with the substrate, and the coating layer is formed on the substrate. A "transfer coater" is a device that can perform transfer coating.

[0050] "Doctor blade" refers to the process of forming a large-area film on a rigid or flexible substrate. The coating blade, or doctor blade, is used to control the thickness of the coating layer by adjusting the gap between the coating blade and the substrate surface. This allows for variations in the thickness of the coating layer. A "doctor blade coater" refers to a device capable of performing doctor blade application.

[0051] Slot die coating is a process for forming large-area films on rigid or flexible substrates. The substrate is continuously fed towards a nozzle on a roller, and a slurry is continuously applied from the nozzle. The thickness of the coating can be controlled in various ways, such as by changing the slurry flow rate or the roller rotation speed. A slot die coater refers to a device that can perform slot die coating.

[0052] The term "room temperature" means an indoor temperature between approximately 18°C ​​and approximately 30°C, for example, an indoor temperature of 18°C, 19°C, 20°C, 21°C, 22°C, 23°C, 24°C, 25°C, 26°C, 27°C, 28°C, 29°C, or 30°C. In some embodiments, room temperature refers to a temperature of approximately 20°C ± 1°C or ± 2°C or ± 3°C. In other embodiments, room temperature refers to a temperature of approximately 22°C or approximately 25°C.

[0053] In a given region, the term "specific humidity" refers to the mass of water vapor present per unit mass of air within that region.

[0054] The term "solids content" refers to the amount of non-volatile substances remaining in a mixture after evaporation. The term "solids content" in relation to a mixture refers to these non-volatile substances. The term "liquid content" refers to the amount of substances evaporated from the mixture. The term "liquid portion" in relation to a mixture refers to these evaporated materials. The sum of the solids content and liquid content of a mixture is added to the total mass of the mixture. The solids and / or liquid content of a mixture is often expressed as a percentage of the total mass of the mixture. If a mixture contains no liquid, its solids content is 100% and its liquid content is 0%.

[0055] The term "peel strength" refers to the force required to separate two materials that are bonded together, such as a current collector and an electrode layer applied to it. It is an indicator of the adhesive strength between two materials and is usually expressed in N / cm.

[0056] The term "C-rate" refers to the charging or discharging speed of a cell or battery, and its total storage capacity is expressed in Ah or mAh. For example, 1C means that the entire stored energy is used in 1 hour, 0.1C means that 10% of the energy is used in 11 hours, or that the entire energy is used in 10 hours, and 5C means that the entire energy is used in 12 minutes.

[0057] An "ampere-hour (Ah)" is a unit that represents the amount of charge stored in a battery. For example, a 1Ah battery can supply current at 1A for 1 hour, 0.5A for 2 hours, and so on. Therefore, 1 ampere-hour (Ah) is equivalent to 3,600 coulombs of charge. Similarly, the term "milliampere-hour (mAh)" also refers to a unit of charge stored in a battery, and is 1 / 1000th of an ampere-hour.

[0058] The term "capacity" refers to a characteristic of electrochemical batteries, specifically the total amount of charge that an electrochemical battery, such as a battery, can hold. Capacity is usually expressed in ampere-hours. The term "specific capacity" refers to the capacity output of an electrochemical cell, such as a battery, per unit weight, and is usually expressed in Ah / kg or mAh / g.

[0059] In the following description, all numerical values ​​disclosed herein are approximations, whether the words “about” or “approximate” are used in relation thereto. They may vary by 1%, 2%, 5%, and in some cases, 10 to 20%. Whenever a numerical range with a lower limit RL and an upper limit RU is disclosed, any numerical values ​​that fall within that range are specifically disclosed. In particular, numerical values ​​within the following range are specifically disclosed: R = RL + (k) * (RU - RL), where k is a variable ranging from 0% to 100%. Furthermore, any numerical range defined by two R numbers as defined above is also specifically disclosed.

[0060] In this specification, all singular references include plural references, and vice versa.

[0061] Currently, electrodes are often prepared by dispersing an electrode active material, a binder composition, and a conductive agent in a solvent to form an electrode slurry, and then applying the electrode slurry onto a current collector and drying it.

[0062] While PVDF is widely used as a binder composition and NMP as a solvent in electrode slurries, the use of NMP poses significant environmental, health, and safety risks. Therefore, using NMP requires the introduction of a vapor recovery system, which is costly. As a safer and more environmentally friendly method, a water-based electrode slurry consisting of a water-compatible binder polymer and an aqueous solvent has been proposed.

[0063] However, such water-compatible polymers often exist in the form of wet binder compositions consisting of the polymer and a large amount of aqueous solvent derived from the polymer's manufacturing process. This presents logistical problems because the large amount of aqueous solvent makes it difficult to store or transport the wet binder composition in considerable quantities.

[0064] For water-insoluble polymers such as PVDF, substantially water-free binder compositions are readily available. In fact, such binder compositions are successfully incorporated into dry electrode mixtures. However, converting wet binder compositions to dry binder compositions can be difficult because water-compatible polymers undergo irreversible morphological changes upon dehydration, and even rehydration may degrade binder performance. Due to the intrinsic affinity of water-compatible polymers to aqueous solvents in the binder composition, reducing the liquid content of wet binder compositions by removing aqueous solvents can be challenging.

[0065] Disclosed herein are binder compositions comprising a water-compatible copolymer, wherein the binder composition has a reduced liquid content compared to conventional wet binder compositions. In some embodiments, the binder composition is produced by processing a wet binder composition comprising the copolymer and an aqueous solvent remaining from the polymerization process. In some embodiments, the processed binder composition is a dry binder composition, i.e., a binder composition that is substantially liquid-free or contains no liquid. In certain embodiments, the processed binder composition is a semi-dry binder composition, i.e., the binder composition still contains liquid, but the liquid content is lower than that of a wet binder composition. In this specification, the liquid portion of a semi-dry binder composition is referred to as its aqueous solvent. The binder compositions disclosed herein have been found to have excellent binder performance.

[0066] In some embodiments, the water-compatible copolymers disclosed herein are produced by polymerization of monomers, polymers, or monomer-polymer complexes dispersed in an aqueous medium, the polymerization being initiated by free radicals generated by a water-soluble free radical initiator. The polymerization process can be carried out using any suitable reaction conditions, as long as the copolymerization is successful.

[0067] In polymerization, the aqueous medium acts as a free radical initiator and a solvent for other chemicals required in the polymerization process. In some embodiments, the aqueous medium is water. In some embodiments, the aqueous medium is selected from the group consisting of tap water, bottled water, purified water, pure water, distilled water, deionized water (DI water), D2O, and combinations thereof.

[0068] In some embodiments, the aqueous medium is a mixture of water and a minor component. In some embodiments, the volume ratio of water to the minor component is about 51:49 to about 99:1. Any water-miscible solvent or volatile solvent can be used as a minor component of the aqueous medium. Some non-limiting examples of water-miscible solvents or volatile solvents include alcohols, lower aliphatic ketones, lower alkyl acetates, and combinations thereof.

[0069] Some non-limiting examples of alcohols include C1-C4 alcohols, such as methanol, ethanol, isopropanol, n-propanol, tert-butanol, n-butanol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 2,3-butanediol, ethylene glycol, propylene glycol, glycerol, and combinations thereof. Some non-limiting examples of lower aliphatic ketones include acetone, dimethyl ketone, methyl ethyl ketone (MEK), and combinations thereof. Some non-limiting examples of lower alkyl acetates include ethyl acetate (EA), isopropyl acetate, propyl acetate, butyl acetate (BA), and combinations thereof. Some other non-limiting examples of water-miscible or volatile solvents include 1,4-dioxane, diethyl ether, methyl tert-butyl ether, cyclopentyl methyl ether, tetrahydrofuran (THF), 2-methyltetrahydrofuran, acetonitrile, dimethyl sulfoxide (DMSO), sulfolane, nitromethane, propylene carbonate, ethylene carbonate, dimethyl carbonate, pyridine, acetaldehyde, formic acid, acetic acid, propanoic acid, butyric acid, γ-valerolactone (GVL), furfuryl alcohol, methyl lactate, ethyl lactate, diethanolamine, dimethylacetamide (DMSO), dimethylacetamide (DMAc), dimethylformamide (DMF), N-methylpyrrolidone (NMP), and dihydrolevoglucocenone (Cyrene). TM These are N,N'-dimethylpropylene urea (DMPU) and dimethyl isosorbite (DMI). In some embodiments, trace components are not present in the aqueous medium.

[0070] In some embodiments, the water-compatible copolymer comprises a structural unit (a) derived from an acid group-containing monomer, where the acid group is selected from the group consisting of carboxylic acids, sulfonic acids, sulfuric acids, phosphonic acids, phosphoric acids, nitric acids, salts of these acids, derivatives of these acids, and combinations thereof. In some embodiments, the acid salt comprises an alkali metal cation. Examples of alkali metals include lithium, sodium, and potassium. In some embodiments, the acid salt comprises an ammonium cation. In some embodiments, the acid group is specifically a combination of one or more of the above acids and one or more salts of the above acids.

[0071] In some embodiments, the carboxylic acid is acrylic acid, methacrylic acid, crotonic acid, 2-butyl crotonic acid, cinnamic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, itaconic anhydride, tetraconic acid, or a combination thereof. In certain embodiments, carboxylic acids include 2-ethylacrylic acid, isocrotonic acid, cis-2-pentenoic acid, trans-2-pentenoic acid, anguateic acid, tiglitic acid, 3,3-dimethylacrylic acid, 3-propylacrylic acid, 2-methyl-3-ethylacrylic acid, cis-2-methyl-3-ethylacrylic acid, 3-isopropylacrylic acid, trans-3-methylacrylic acid, cis-3-methyl-3-ethylacrylic acid, 2-isopropylacrylic acid, trimethylacrylic acid, 2-methyl-3,3-diethylacrylic acid, 3-butylacrylic acid, 2-butylacrylic acid, 2-pentylacrylic acid, 2-methyl-2-hexenoic acid, trans-3-methyl-2-hexenoic acid, 3-methyl-3-propylacrylic acid, 2-ethyl-3-propyl These include propyl acrylic acid, 2,3-diethyl acrylic acid, 3,3-diethyl acrylic acid, 3-methyl-3-hexyl acrylic acid, 3-methyl-3-tert-butyl acrylic acid, 2-methyl-3-pentyl acrylic acid, 3-methyl-2-hexenoic acid, 4-ethyl-2-hexenoic acid, 2-methyl ethyl ester, 3-tertyl acrylic acid, 2,3-dimethyl-3-ethyl acrylic acid, 3,3-dimethyl-2-ethyl acrylic acid, 3-methyl-3-isopropyl acrylic acid, 2-methyl-3-isopropyl acrylic acid, trans-2-octenoic acid, cis-2-octenoic acid, trans-2-decenoic acid, α-acetoxyacrylic acid, β-trans-alyloxyacrylic acid, α-chloro-β-E-methoxyacrylic acid, or a combination thereof. In some embodiments, the carboxylic acid is methyl maleate, dimethyl maleate, phenyl maleate, bromo maleate, chloromaleic acid, dichloromaleic acid, fluoromaleic acid, nonyl maleate, decyl hydrogen maleate, dodecyl hydrogen maleate, octadecyl hydrogen maleate, fluoroalkyl hydrogen, or a combination thereof.In some embodiments, the carboxylic acid is maleic anhydride, methyl maleic anhydride, dimethyl maleic anhydride, acrylic anhydride, methacrylic anhydride, methacrolein, methacryloyl chloride, methacryloyl fluoride, methacryloyl bromide, or a combination thereof.

[0072] In some embodiments, the sulfonic acid is vinyl sulfonic acid, methyl vinyl sulfonic acid, aryl vinyl sulfonic acid, aryl sulfonic acid, methallyl sulfonic acid, styrene sulfonic acid, 2-sulfoethyl methacrylic acid, 2-methylprop-2-ene-1-sulfonic acid, 2-acrylamido-2-methyl-1-propanesulfonic acid, 3-alyloxy-2-hydroxy-1-propanesulfonic acid, or a combination thereof.

[0073] In some embodiments, the sulfuric acid is an aryl sulfate, a vinyl sulfate, 4-arylphenol sulfate, or a combination thereof.

[0074] In some embodiments, the phosphonic acid is vinylphosphonic acid, arylphosphonic acid, vinylbenzylphosphonic acid, acrylamidealkylphosphonic acid, methacrylamidealkylphosphonic acid, acrylamidealkyldiphonic acid, acryloylphosphonic acid, 2-methacryloyloxyethylphosphonic acid, bis(2-methacryloyloxyethyl)phosphonic acid, ethylene 2-methacryloyloxyethylphosphonic acid, ethyl-methacryloyloxyethylphosphonic acid, or a combination thereof.

[0075] In some embodiments, phosphoric acid is mono(2-acryloyloxyethyl) phosphate, mono(2-methacryloyloxyethyl) phosphate, diphenyl(2-acryloyloxyethyl) phosphate, diphenyl(2-methacryloyloxyethyl) phosphate, phenyl(2-acryloyloxyethyl) phosphate, methacrylate phosphate oxyethyl, 3-chloro-2-phosphoryloxypropyl methacrylate, phosphoryloxypoly(ethylene glycol) monomethacrylate, phosphoryloxypoly(propylene glycol) methacrylate, (meth)acryloyloxyethyl phosphate, (meth)acryloyloxypropyl phosphate, (meth)acryloyl Acryloyloxy-2-hydroxypropyl phosphate, (meth)acryloyloxy-3-hydroxypropyl phosphate, (meth)acryloyloxy-3-chloro-2-hydroxypropyl phosphate, aryl hydrogen phosphate, vinyl hydrogen phosphate, aryl hydrogen pyrophosphate, vinyl hydrogen pyrophosphate, aryl hydrogen tripolyphosphate, vinyl hydrogen tripolyphosphate, aryl hydrogen tetrapolyphosphate, vinyl hydrogen tetrapolyphosphate, aryl hydrogen trimaphosphate, vinyl hydrogen trimaphosphate, isopentenyl phosphate, isopentenyl pyrophosphate, or a combination thereof, where (meth)acryloyl- represents acryloyl- or methacrylylloyl-.

[0076] In some embodiments, nitric acid is an aryl hydrogen nitrate, an ethenyl hydrogen nitrate, or a combination thereof.

[0077] In some embodiments, the proportion of structural units (a) in the water-compatible copolymer is based on the total number of moles of monomer units in the copolymer, from about 5 mol% to about 95 mol%, from about 5 mol% to about 90 mol%, from about 5 mol% to about 85 mol%, from about 5 mol% to about 80 mol%, from about 5 mol% to about 75 mol%, from about 5 mol% to about 70 mol%, from about 5 mol% to about 65 mol%, from about 5 mol% to about 60 mol%, from about 5 mol% to about 55 mol%, from about 5 mol% to about 50 mol%, from about 5 mol% to about 45 mol%, from about 5 mol% to about 40 mol%, from about 5 mol% to about 35 mol%, from about 5 mol% to about 30 mol%, from about 5 mol% to about 25 mol%, from about 10 mol% to about 95 mol%, from about 10 mol% to about 90 mol%, from about 10 mol% to about 85 mol%, from about 10 mol% to about 80 mol%, approximately 10 mol% to approximately 75 mol%, approximately 10 mol% to approximately 75 mol%, approximately 10 mol% to approximately 65 mol%, approximately 10 mol% to approximately 65 mol%, approximately 10 mol% to approximately 55 mol%, approximately 10 mol% to approximately 50 mol%, approximately 10 mol% to approximately 45 mol%, approximately 10 mol% to approximately 40 mol%, approximately 10 mol% to approximately 35 mol%, approximately 10 mol% to approximately 30 mol%, approximately 15 mol% From approximately 95 mol%, from approximately 15 mol% to approximately 90 mol%, from approximately 15 mol% to approximately 85 mol%, from approximately 15 mol% to approximately 80 mol%, from approximately 15 mol% to approximately 75 mol%, from approximately 15 mol% to approximately 70 mol%, from approximately 15 mol% to approximately 65 mol%, from approximately 15 mol% to approximately 60 mol%, from approximately 15 mol% to approximately 55 mol%, from approximately 15 mol% to approximately 45 mol%, from approximately 15 mol% to approximately 35 mol%, from approximately 20 mol% to approximately 95 mol%, from approximately 20 mol% to approximately 90 mol%, approximately 20 From mol% to approximately 85 mol%, from approximately 20 mol% to approximately 80 mol%, from approximately 20 mol% to approximately 75 mol%, from approximately 20 mol% to approximately 70 mol%, from approximately 20 mol% to approximately 65 mol%, from approximately 20 mol% to approximately 60 mol%, from approximately 20 mol% to approximately 55 mol%, from approximately 20 mol% to approximately 50 mol%, from approximately 20 mol% to approximately 45 mol%, from approximately 20 mol% to approximately 40 mol%, from approximately 25 mol% to approximately 95 mol%, approximately 25 mol% to approximately 90 mol%, approximately 25 mol% to approximately 85 mol%, approximately 25 mol% to approximately 80 mol%, approximately 25 mol% to approximately 75 mol%, approximately 25 mol% to approximately 70 mol%, approximately 25 mol% to approximately 65 mol%, approximately 25 mol% to approximately 65 mol%, approximately 25 mol% to approximately 55 mol%, approximately 25 mol% to approximately 50 mol%, approximately 25 mol% to approximately 45 mol,Approximately 30 mol% to approximately 95 mol%, approximately 30 mol% to approximately 90 mol%, approximately 30 mol% to approximately 85 mol%, approximately 30 mol% to approximately 80 mol%, approximately 30 mol% to approximately 75 mol%, approximately 30 mol% to approximately 70 mol%, approximately 30 mol% to approximately 65 mol%, approximately 30 mol% to approximately 60 mol%, approximately 30 mol% to approximately 55 mol%, approximately 30 mol% to approximately 50 mol%, approximately 35 mol% to approximately 95 mol%, approximately 35 mol% to approximately 90 mol%, approximately 35 mol% to approximately 85 mol%, approximately 35 mol% to approximately 80 mol%, approximately 35 From mol% to approximately 75 mol%, from approximately 35 mol% to approximately 70 mol%, from approximately 35 mol% to approximately 65 mol%, from approximately 35 mol% to approximately 60 mol%, from approximately 35 mol% to approximately 55 mol%, from approximately 40 mol% to approximately 95 mol%, from approximately 40 mol% to approximately 90 mol%, from approximately 40 mol% to approximately 85 mol%, from approximately 40 mol% to approximately 80 mol%, from approximately 40 mol% to approximately 75 mol%, from approximately 40 mol% to approximately 70 mol%, from approximately 40 mol% to approximately 65 mol%, from approximately 40 mol% to approximately 60 mol%, from approximately 40 mol% to approximately 75 mol%, and approximately 45 mol% From 0% to approximately 95 mol%, from approximately 45 mol% to approximately 90 mol%, from approximately 45 mol% to approximately 85 mol%, from approximately 45 mol% to approximately 80 mol%, from approximately 45 mol% to approximately 75 mol%, from approximately 45 mol% to approximately 70 mol%, from approximately 45 mol% to approximately 65 mol%, from approximately 50 mol% to approximately 95 mol%, from approximately 50 mol% to approximately 90 mol%, from approximately 50 mol% to approximately 85 mol%, from approximately 50 mol% to approximately 80 mol%, from approximately 50 mol% to approximately 75 mol%, from approximately 50 mol% to approximately 70 mol%, from approximately 55 mol% to approximately 95 mol%, and approximately 55 mol% The percentages are approximately 55 mol% to 90 mol%, approximately 55 mol% to 85 mol%, approximately 55 mol% to approximately 80 mol%, approximately 55 mol% to approximately 75 mol%, approximately 60 mol% to approximately 95 mol%, approximately 60 mol% to approximately 90 mol%, approximately 60 mol% to approximately 85 mol%, approximately 60 mol% to approximately 80 mol%, approximately 65 mol% to approximately 95 mol%, approximately 65 mol% to approximately 85 mol%, approximately 70 mol% to approximately 95 mol%, approximately 75 mol% to approximately 90 mol%, approximately 80 mol% to approximately 95 mol%, or approximately 80 mol% to approximately 90 mol%.

[0078] In some embodiments, the proportion of structural units (a) in the water-compatible copolymer is about 5 mol%, about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mol%, about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%, about 16 mol%, about 17 mol%, about 18 mol%, about 19 mol%, about 20 mol%, about 21 mol%, based on the total number of moles of monomer units in the copolymer. Approximately 22 mol%, approximately 23 mol%, approximately 24 mol%, approximately 25 mol%, approximately 26 mol%, approximately 27 mol%, approximately 28 mol%, approximately 29 mol%, approximately 30 mol%, approximately 31 mol%, approximately 32 mol%, approximately 33 mol%, approximately 34 mol%, approximately 35 mol%, approximately 36 mol%, approximately 37 mol%, approximately 38 mol%, approximately 39 mol%, approximately 40 mol%, approximately 41 mol%, approximately 42 mol%, approximately 43 mol%, approximately 44 mol%, approximately 45 mol%, approximately 46 mol% Approximately 47 mol%, approximately 48 mol%, approximately 49 mol%, approximately 50 mol%, approximately 51 mol%, approximately 52 mol%, approximately 53 mol%, approximately 54 mol%, approximately 55 mol%, approximately 56 mol%, approximately 57 mol%, approximately 58 mol%, approximately 59 mol%, approximately 60 mol%, approximately 61 mol%, approximately 62 mol%, approximately 63 mol%, approximately 64 mol%, approximately 65 mol%, approximately 66 mol%, approximately 67 mol%, approximately 68 mol%, approximately 69 mol%, approximately 70 mol%, approximately 71 mol These are approximately 72 mol%, 73 mol%, 74 mol%, 75 mol%, 76 mol%, 77 mol%, 78 mol%, 79 mol%, 80 mol%, 81 mol%, 82 mol%, 83 mol%, 84 mol%, 85 mol%, 86 mol%, 87 mol%, 88 mol%, 89 mol%, 90 mol%, 91 mol%, 92 mol%, 93 mol%, 94 mol%, or 95 mol%.

[0079] In some embodiments, the proportion of structural units (a) in the water-compatible copolymer is less than 95 mol%, less than 90 mol%, less than 85 mol%, less than 80 mol%, less than 75 mol%, less than 70 mol%, less than 65 mol%, less than 60 mol%, less than 55 mol%, less than 50 mol%, less than 45 mol%, less than 40 mol%, less than 35 mol%, less than 30 mol%, less than 25 mol%, less than 20 mol%, or less than 15 mol%, based on the total number of moles of monomer units in the copolymer. In some embodiments, the proportion of structural units (a) in the water-compatible copolymer is greater than 5 mol%, greater than 10 mol%, greater than 15 mol%, greater than 20 mol%, greater than 25 mol%, greater than 30 mol%, greater than 35 mol%, greater than 40 mol%, greater than 45 mol%, greater than 50 mol%, greater than 55 mol%, greater than 60 mol%, greater than 65 mol%, greater than 70 mol%, greater than 75 mol%, greater than 80 mol%, or greater than 85 mol%, based on the total number of moles of monomer units in the copolymer.

[0080] In some embodiments, the water-compatible copolymer further comprises structural units (b) derived from monomers selected from the group consisting of amide group-containing monomers, hydroxyl group-containing monomers, and combinations thereof.

[0081] In some embodiments, the amide group-containing monomers are acrylamide, methacrylamide, N-methylmethacrylamide, N-ethylmethacrylamide, Nn-propylmethacrylamide, N-isopropylmethacrylamide, isopropylacrylamide, Nn-butylmethacrylamide, N-isobutylmethacrylamide, N,N-dimethylacrylamide, N,N-dimethylmethacrylamide, N,N-diethylacrylamide, N,N-diethylmethacrylamide, N-methylolmethacrylamide, N-(methoxymethyl)methacrylamide, N-(ethoxymethyl)methacrylamide, These include N-(propoxymethyl)methacrylamide, N-(butoxymethyl)methacrylamide, N,N-dimethylmethacrylamide, N,N-dimethylaminopropylmethacrylamide, N,N-dimethylaminoethylmethacrylamide, N,N-dimethylolmethacrylamide, diaketonemethacrylamide, diacetone acrylamide, methacryloylmorpholine, N-hydroxylmethacrylamide, N-methoxymethylacrylamide, N-methoxymethylmethacrylamide, N,N'-methylenebisacrylamide (MBA), N-hydroxymethylacrylamide, or combinations thereof.

[0082] In some embodiments, the hydroxyl group-containing monomer is a C1-C group having a hydroxyl group. 20 Alkyl or C5-C 20The monomer is an acrylate or methacrylate containing a cycloalkyl group. In some embodiments, the hydroxyl group-containing monomer is 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 2-hydroxybutyl methacrylate, 3-hydroxypropyl acrylate, 3-hydroxypropyl methacrylate, 4-hydroxybutyl methacrylate, 5-hydroxypentyl acrylate, 6-hydroxyhexyl methacrylate, 1,4-cyclohexanedimethanol mono(meth)acrylate, 3-chloro-2-hydroxypropyl methacrylate, diethylene glycol mono(meth)acrylate, aryl alcohols, or a combination thereof.

[0083] In some embodiments, the proportion of structural units (b) in the water-compatible copolymer is approximately 5 mol% to approximately 95 mol%, approximately 5 mol% to approximately 90 mol%, approximately 5 mol% to approximately 85 mol%, approximately 5 mol% to approximately 80 mol%, approximately 5 mol% to approximately 75 mol%, approximately 5 mol% to approximately 70 mol%, approximately 5 mol% to approximately 65 mol%, approximately 5 mol% to approximately 60 mol%, approximately 5 mol% to approximately 55 mol%, approximately 5 mol% to approximately 50 mol%, approximately 5 mol% to approximately 45 mol%, approximately 5 mol% to approximately 40 mol%, approximately 5 mol% to approximately 35 mol%, and approximately 5 mol%. From approximately 30 mol%, from approximately 5 mol% to approximately 25 mol%, from approximately 10 mol% to approximately 95 mol%, from approximately 10 mol% to approximately 90 mol%, from approximately 10 mol% to approximately 85 mol%, from approximately 10 mol% to approximately 80 mol%, from approximately 10 mol% to approximately 75 mol%, from approximately 10 mol% to approximately 70 mol%, from approximately 10 mol% to approximately 65 mol%, from approximately 10 mol% to approximately 60 mol%, from approximately 10 mol% to approximately 55 mol%, from approximately 10 mol% to approximately 50 mol%, from approximately 10 mol% to approximately 45 mol%, from approximately 10 mol% to approximately 40 mol%, from approximately 10 mol% to approximately 35 mol%, from approximately 10 mol% to approximately 30 mol%, and from approximately 15 mol% to approximately 95 mol%. , approximately 15 mol% to approximately 90 mol%, approximately 15 mol% to approximately 85 mol%, approximately 15 mol% to approximately 80 mol%, approximately 15 mol% to approximately 75 mol%, approximately 15 mol% to approximately 70 mol%, approximately 15 mol% to approximately 65 mol%, approximately 15 mol% to approximately 60 mol%, approximately 15 mol% to approximately 55 mol%, approximately 15 mol% to approximately 45 mol%, approximately 15 mol% to approximately 35 mol%, approximately 20 mol% to approximately 95 mol%, approximately 20 mol% to approximately 90 mol%, approximately 20 mol% to approximately 85 mol%, approximately 20 mol% to approximately 80 mol%, approximately 20 mol% to approximately 75 mol%, approximately 20 mol% to approximately 70 mol%, approximately 20 mol% to Approximately 65 mol%, approximately 20 mol% to approximately 60 mol%, approximately 20 mol% to approximately 55 mol%, approximately 20 mol% to approximately 50 mol%, approximately 20 mol% to approximately 45 mol%, approximately 20 mol% to approximately 40 mol%, approximately 25 mol% to approximately 95 mol%, approximately 25 mol% to approximately 95 mol%, approximately 25 mol% to approximately 85 mol%, approximately 25 mol% to approximately 80 mol%, approximately 25 mol% to approximately 75 mol%, approximately 25 mol% to approximately 70 mol%, approximately 25 mol% to approximately 60 mol%, approximately 25 mol% to approximately 55 mol%, approximately 25 mol% to approximately 50 mol%, approximately 25 mol% to approximately 45 mol%, approximately 30 mol% to approximately 95 mol,Approximately 30 mol% to approximately 90 mol%, approximately 30 mol% to approximately 85 mol%, approximately 30 mol% to approximately 80 mol%, approximately 30 mol% to approximately 75 mol%, approximately 30 mol% to approximately 70 mol%, approximately 30 mol% to approximately 65 mol%, approximately 30 mol% to approximately 60 mol%, approximately 30 mol% to approximately 55 mol%, approximately 35 mol% to approximately 95 mol%, approximately 35 mol% to approximately 90 mol%, approximately 35 mol% to approximately 85 mol%, approximately 35 mol% to approximately 80 mol%, approximately 35 mol% to approximately 75 mol, Approximately 35 mol% to approximately 70 mol%, approximately 35 mol% to approximately 65 mol%, approximately 35 mol% to approximately 60 mol%, approximately 35 mol% to approximately 55 mol%, approximately 40 mol% to approximately 95 mol%, approximately 40 mol% to approximately 90 mol%, approximately 40 mol% to approximately 85 mol%, approximately 40 mol% to approximately 80 mol%, approximately 40 mol% to approximately 75 mol%, approximately 40 mol% to approximately 70 mol%, approximately 40 mol% to approximately 65 mol%, approximately 45 mol% to approximately 95 mol%, approximately 45 mol% to approximately 90 mol%, approximately 4 5 mol% to approximately 85 mol%, approximately 45 mol% to approximately 80 mol%, approximately 45 mol% to approximately 75 mol%, approximately 45 mol% to approximately 70 mol%, approximately 45 mol% to approximately 65 mol%, approximately 50 mol% to approximately 95 mol%, approximately 50 mol% to approximately 90 mol%, approximately 50 mol% to approximately 85 mol%, approximately 50 mol% to approximately 80 mol%, approximately 50 mol% to approximately 75 mol%, approximately 50 mol% to approximately 75 mol%, approximately 55 mol% to approximately 95 mol%, approximately 55 mol% to approximately 90 mol%, approximately 55 mol% The percentages are approximately 55 mol% to 85 mol%, approximately 55 mol% to 80 mol%, approximately 55 mol% to 75 mol%, approximately 60 mol% to 95 mol%, approximately 60 mol% to 90 mol%, approximately 60 mol% to 85 mol%, approximately 60 mol% to 80 mol%, approximately 65 mol% to 95 mol%, approximately 65 mol% to 85 mol%, approximately 70 mol% to 95 mol%, approximately 75 mol% to 90 mol%, approximately 80 mol% to 95 mol%, or approximately 80 mol% to 90 mol%.

[0084] In some embodiments, the proportion of structural units (b) in the water-compatible copolymer is approximately 5 mol%, approximately 6 mol%, approximately 7 mol%, approximately 8 mol%, approximately 9 mol%, approximately 10 mol%, approximately 11 mol%, approximately 12 mol%, approximately 13 mol%, approximately 14 mol%, approximately 15 mol%, approximately 16 mol%, approximately 17 mol%, approximately 18 mol%, approximately 19 mol%, approximately 20 mol%, approximately 21 mol%, approximately 22 mol%, approximately 23 mol%, approximately 24 mol%, approximately 25 mol%, and approximately 26 mol%, based on the total number of moles of monomer units in the copolymer. %, approximately 27 mol%, approximately 28 mol%, approximately 29 mol%, approximately 30 mol%, approximately 31 mol%, approximately 32 mol%, approximately 33 mol%, approximately 34 mol%, approximately 35 mol%, approximately 36 mol%, approximately 37 mol%, approximately 38 mol%, approximately 39 mol%, approximately 40 mol%, approximately 41 mol%, approximately 42 mol%, approximately 43 mol%, approximately 44 mol%, approximately 45 mol%, approximately 46 mol%, approximately 47 mol%, approximately 48 mol%, approximately 49 mol%, approximately 49 mol%, approximately 47 mol%, approximately 47 mol%, approximately 48 mol%, approximately 48 mol%, approximately 47 mol%. Approximately 50 mol%, approximately 51 mol%, approximately 52 mol%, approximately 53 mol%, approximately 54 mol%, approximately 55 mol%, approximately 56 mol%, approximately 57 mol%, approximately 58 mol%, approximately 59 mol%, approximately 60 mol%, approximately 61 mol%, approximately 62 mol%, approximately 63 mol%, approximately 64 mol%, approximately 65 mol%, approximately 66 mol%, approximately 67 mol%, approximately 68 mol%, approximately 69 mol%, approximately 70 mol%, approximately 71 mol%, approximately 72 mol%, approximately 73 mol% The percentages are approximately 74 mol%, 75 mol%, 76 mol%, 75 mol%, 77 mol%, 78 mol%, 79 mol%, 80 mol%, 81 mol%, 82 mol%, 83 mol%, 84 mol%, 85 mol%, 86 mol%, 87 mol%, 88 mol%, 89 mol%, 90 mol%, 91 mol%, 92 mol%, 93 mol%, 94 mol%, or 95 mol%.

[0085] In some embodiments, the proportion of structural units (b) in the water-compatible copolymer is less than 95 mol%, less than 90 mol%, less than 85 mol%, less than 80 mol%, less than 75 mol%, less than 70 mol%, less than 65 mol%, less than 60 mol%, less than 55 mol%, less than 50 mol%, less than 45 mol%, less than 40 mol%, less than 35 mol%, less than 30 mol%, less than 25 mol%, less than 20 mol%, or less than 15 mol%, based on the total number of moles of monomer units in the copolymer. In some embodiments, the proportion of structural units (b) in the water-compatible copolymer is greater than 5 mol%, greater than 10 mol%, greater than 15 mol%, greater than 20 mol%, greater than 25 mol%, greater than 30 mol%, greater than 35 mol%, greater than 40 mol%, greater than 45 mol%, greater than 50 mol%, greater than 55 mol%, greater than 60 mol%, greater than 65 mol%, greater than 70 mol%, greater than 75 mol%, greater than 80 mol%, or greater than 85 mol%, based on the total number of moles of monomer units in the copolymer.

[0086] In some embodiments, the water-compatible copolymer further comprises structural units (c) derived from monomers selected from the group consisting of nitrile group-containing monomers, ester group-containing monomers, ether group-containing monomers, epoxy group-containing monomers, carbonyl group-containing monomers, fluorine-containing monomers, and combinations thereof.

[0087] In some embodiments, the nitrile group-containing monomer includes α,β-ethylenically unsaturated nitrile monomers. In some embodiments, the nitrile group-containing monomer is acrylonitrile, α-halogenoacrylonitrile, α-alkylacrylonitrile, or a combination thereof. In some embodiments, the nitrile group-containing monomer is α-chloroacrylonitrile, α-bromoacrylonitrile, α-fluoroacrylonitrile, methacrylonitrile, α-ethylacrylonitrile, α-isopropylacrylonitrile, α-n-hexylacrylonitrile, α-methoxyacrylonitrile, 3-methoxyacrylonitrile, 3-ethoxyacrylonitrile, α-acetoxyacrylonitrile, α-phenylacrylonitrile, α-tolylacrylonitrile, α-(methoxyphenyl)acrylonitrile, α-(chlorophenyl)acrylonitrile, α-(cyanophenyl)acrylonitrile, vinylidene cyanide, or a combination thereof.

[0088] In some embodiments, the ester group-containing monomer is C1-C 20 Alkyl acrylate, C1-C 20These are alkyl methacrylates, cycloalkyl acrylates, or combinations thereof. In some embodiments, the ester group-containing monomers are methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, sec-butyl acrylate, tert-butyl acrylate, pentyl acrylate, hexyl acrylate, heptyl acrylate, octyl acrylate, 3,3,5-trimethylhexyl, 2-ethylhexyl acrylate, nonyl acrylate, decyl acrylate, lauryl acrylate, n-tetradecyl acrylate, octadecyl acrylate, cyclohexyl acrylate, phenyl acrylate, methoxymethyl acrylate, methoxyethyl acrylate, ethoxymethyl acrylate, ethoxyethyl acrylate, perfluorooctyl acrylate, stearyl acrylate, or combinations thereof. In some embodiments, the ester group-containing monomer is cyclohexyl acrylate, cyclohexyl methacrylate methacrylate, isobornyl acrylate, isobornyl methacrylate, 3,3,5-trimethylcyclohexyl acrylate, or a combination thereof. In some embodiments, the ester group-containing monomer is methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, sec-butyl methacrylate, tert-butyl methacrylate, isobutyl methacrylate, n-pentyl methacrylate, isopentyl methacrylate, hexyl methacrylate, heptyl methacrylate, octyl methacrylate, 2-ethylhexyl methacrylate, nonyl methacrylate, decyl methacrylate, lauryl methacrylate, n-tetradecyl methacrylate, stearyl methacrylate, 2,2,2-trifluoroethyl methacrylate, phenyl methacrylate, benzyl methacrylate, or a combination thereof.

[0089] In some embodiments, the ether group-containing monomer is vinyl ether, aryl ether, aryl vinyl ether, aryl glycidyl ether, 2H-hexafluoroisopropyl aryl ether, hydroxypolyethoxy(10) aryl ether, aryl phenethyl ether, ethyl vinyl ether, propyl vinyl ether, N-butyl vinyl ether, or a combination thereof.

[0090] In some embodiments, the epoxy group-containing monomers are vinyl glycidyl ether, aryl glycidyl ether, aryl-2,3-epoxypropyl ether, butenyl glycidyl ether, butadiene monoepoxide, chloroprene monoepoxide, 3,4-epoxy-1-butene, 4,5-epoxy-2-pentene, 3,4-epoxy-1-vinylcyclohexane, 1,2-epoxy-4-vinylcyclohexane, 3,4-epoxycyclohexylene, epoxy-4-vinylcyclohexene, 1,2-epoxy-5,9-cyclododecadine, or a combination thereof. In some embodiments, the epoxy group-containing monomer is 1,2-epoxy-5-hexene, 1,2-epoxy-9-decene, glycidyl acrylate, glycidyl methacrylate, glycidyl crotonic acid, glycidyl 2,4-dimethyl penteneate, glycidyl hexenoate, glycidyl 4-heptenoate, glycidyl 5-methyl-4-heptenoate, glycidyl sorbate, glycidyl linoleate, glycidyl oleate, glycidyl 3-butenoate, glycidyl 3-pentenoate, glycidyl-4-methyl-3-pentenoic acid, or a combination thereof.

[0091] In some embodiments, the carbonyl group-containing monomer is methyl vinyl ketone, ethyl vinyl ketone, acrolein, acryloyl chloride, cinnamaldehyde, E-crotonaldehyde, 2-hexenal, octo-2-enal, 2-methylpento-2-enal, 4-methylpento-3-enone, octo-1-en-3-one, 2-pentylbut-1-en-3-one, or a combination thereof.

[0092] In some embodiments, the fluorine-containing monomer is an acrylate or methacrylate containing a C1-C 20 alkyl group, or a combination thereof, where the monomer contains at least one fluorine atom. In some embodiments, the fluorine-containing monomer is a perfluoroalkyl acrylate such as perfluorododecyl acrylate, perfluoro-n-octyl acrylate, perfluoro-n-butyl acrylate, perfluorohexylethyl acrylate, and perfluorooctylethyl acrylate; perfluoroalkyl methacrylates such as perfluorododecyl methacrylate, perfluoro-n-octyl methacrylate, perfluoro-n-butyl methacrylate, perfluorohexylethyl methacrylate, and perfluorooctylethyl methacrylate; perfluorooxyalkyl acrylates such as perfluorododecyloxyethyl acrylate and perfluorodecyloxyethyl acrylate, for example perfluorododecyloxyethyl methacrylate and perfluorodecyloxyethyl methacrylate, or combinations thereof. In some embodiments, the fluorine-containing monomer is a carboxylate containing a C1-C 20 alkyl group and a fluorine atom; where the carboxylate is selected from the group consisting of crotonate, maleate, fumarate, itaconate, or combinations thereof. In some embodiments, the fluorine-containing monomer is vinyl fluoride, trifluoroethylene, trifluorochloroethylene, fluoroalkyl vinyl ether, perfluoroalkyl vinyl ether, hexafluoropropylene, 2,3,3-tetrafluoropropene, vinylidene fluoride, tetrafluoroethylene, 2-fluoroacrylate, or combinations thereof.

[0093] In some embodiments, the proportion of structural units (c) in the water-compatible copolymer is approximately 5 mol% to 95 mol%, approximately 5 mol% to 90 mol%, approximately 5 mol% to 85 mol%, approximately 5 mol% to 80 mol%, approximately 5 mol% to 75 mol%, approximately 5 mol% to 70 mol%, approximately 5 mol% to 65 mol%, approximately 5 mol% to 60 mol%, approximately 5 mol% to 55 mol%, approximately 5 mol% to 50 mol%, approximately 5 mol% to 45 mol%, approximately 5 mol% to 40 mol%, approximately 5 mol% to 35 mol%, and approximately 5 mol%. From approximately 30 mol%, from approximately 5 mol% to approximately 25 mol%, from approximately 10 mol% to approximately 95 mol%, from approximately 10 mol% to approximately 90 mol%, from approximately 10 mol% to approximately 85 mol%, from approximately 10 mol% to approximately 80 mol%, from approximately 10 mol% to approximately 75 mol%, from approximately 10 mol% to approximately 70 mol%, from approximately 10 mol% to approximately 65 mol%, from approximately 10 mol% to approximately 60 mol%, from approximately 10 mol% to approximately 55 mol%, from approximately 10 mol% to approximately 50 mol%, from approximately 10 mol% to approximately 45 mol%, from approximately 10 mol% to approximately 40 mol%, from approximately 10 mol% to approximately 35 mol%, from approximately 10 mol% to approximately 30 mol%, and from approximately 15 mol% to approximately 95 mol%. , approximately 15 mol% to approximately 90 mol%, approximately 15 mol% to approximately 85 mol%, approximately 15 mol% to approximately 80 mol%, approximately 15 mol% to approximately 75 mol%, approximately 15 mol% to approximately 70 mol%, approximately 15 mol% to approximately 65 mol%, approximately 15 mol% to approximately 60 mol%, approximately 15 mol% to approximately 55 mol%, approximately 15 mol% to approximately 45 mol%, approximately 15 mol% to approximately 35 mol%, approximately 20 mol% to approximately 95 mol%, approximately 20 mol% to approximately 90 mol%, approximately 20 mol% to approximately 85 mol%, approximately 20 mol% to approximately 80 mol%, approximately 20 mol% to approximately 75 mol%, approximately 20 mol% to approximately 70 mol%, approximately 20 mol% to Approximately 65 mol%, approximately 20 mol% to approximately 60 mol%, approximately 20 mol% to approximately 55 mol%, approximately 20 mol% to approximately 50 mol%, approximately 20 mol% to approximately 45 mol%, approximately 20 mol% to approximately 40 mol%, approximately 25 mol% to approximately 95 mol%, approximately 25 mol% to approximately 90 mol%, approximately 25 mol% to approximately 85 mol%, approximately 25 mol% to approximately 80 mol%, approximately 25 mol% to approximately 75 mol%, approximately 25 mol% to approximately 70 mol%, approximately 25 mol% to approximately 65 mol%, approximately 25 mol% to approximately 65 mol%, approximately 25 mol% to approximately 55 mol%, approximately 25 mol% to approximately 50 mol%, approximately 25 mol% to approximately 45 mol,Approximately 30 mol% to approximately 95 mol%, approximately 30 mol% to approximately 90 mol%, approximately 30 mol% to approximately 85 mol%, approximately 30 mol% to approximately 80 mol%, approximately 30 mol% to approximately 75 mol%, approximately 30 mol% to approximately 70 mol%, approximately 30 mol% to approximately 65 mol%, approximately 30 mol% to approximately 60 mol%, approximately 30 mol% to approximately 55 mol%, approximately 35 mol% to approximately 95 mol%, approximately 35 mol% to approximately 90 mol%, approximately From 35 mol% to approximately 85 mol%, from approximately 35 mol% to approximately 80 mol%, from approximately 35 mol% to approximately 75 mol%, from approximately 35 mol% to approximately 70 mol%, from approximately 35 mol% to approximately 65 mol%, from approximately 35 mol% to approximately 60 mol%, from approximately 35 mol% to approximately 55 mol%, from approximately 40 mol% to approximately 95%, from approximately 40% to approximately 90%, from approximately 40% to approximately 85%, from approximately 40% to approximately 80%, from approximately 40% to approximately 75%, and from approximately 40%. Approximately 70%, approximately 40% to approximately 65%, approximately 45% to approximately 95%, approximately 45% to approximately 90%, approximately 45% to approximately 85%, approximately 45% to approximately 80%, approximately 45% to approximately 75%, approximately 45% to approximately 70%, approximately 45% to approximately 65%, approximately 50% to approximately 95%, approximately 50% to approximately 90%, approximately 50% to approximately 85%, approximately 50% to approximately 80%, approximately 50% to approximately 75%, approximately 50% to approximately 70%, approximately 55% The percentages are approximately 55% to 95%, 55% to 90%, approximately 55% to 85%, approximately 55% to approximately 80%, approximately 55% to approximately 75%, approximately 60% to approximately 95%, approximately 60% to approximately 90%, approximately 60% to approximately 85%, approximately 60% to approximately 80%, approximately 65% ​​to approximately 95%, approximately 65% ​​to approximately 85%, approximately 70% to approximately 95%, approximately 75% to approximately 90%, approximately 80% to approximately 95%, or approximately 80% to approximately 90%.

[0094] In some embodiments, the proportion of structural units (c) in the water-compatible copolymer is approximately 5 mol%, approximately 6 mol%, approximately 7 mol%, approximately 8 mol%, approximately 9 mol%, approximately 10 mol%, approximately 11 mol%, approximately 12 mol%, approximately 13 mol%, approximately 14 mol%, approximately 15 mol%, approximately 16 mol%, approximately 17 mol%, approximately 18 mol%, approximately 19 mol%, approximately 20 mol%, approximately 21 mol%, approximately 22 mol%, approximately 23 mol%, approximately 24 mol%, approximately 25 mol%, approximately 26 mol%, approximately 27 mol%, approximately 28 mol%, approximately 29 mol%, approximately 30 mol%, approximately 31 mol%, approximately 32 mol%, approximately 33 mol%, approximately 34 mol%, approximately 35 mol%, approximately 36 mol%, and approximately 37 mol%, based on the total number of moles of monomer units in the copolymer. Approximately 38 mol%, approximately 39 mol%, approximately 40 mol%, approximately 41 mol%, approximately 42 mol%, approximately 43 mol%, approximately 44 mol%, approximately 45 mol%, approximately 46 mol%, approximately 47 mol%, approximately 48 mol%, approximately 49 mol%, approximately 49 mol%, approximately 50 mol%, approximately 51 mol%, approximately 52 mol%, approximately 53 mol%, approximately 54 mol%, approximately 55 mol%, approximately 56 mol%, approximately 57 mol%, approximately 58 mol%, approximately 59 mol%, approximately 60 mol%, approximately 61 mol%, approximately 62 mol%, approximately 63 mol%, approximately 64 mol%, approximately 65 mol%, approximately 66 mol%, approximately 67 mol%, approximately 68 mol%, approximately 69 mol%, approximately 70 mol%, approximately 71 mol%, approximately 72 mol%, approximately 73 mol%, approximately 74 mol%, approximately 75 mol%, approximately 76 mol%, approximately 75 mol%. Approximately 77 mol%, approximately 78 mol%, approximately 79 mol%, approximately 80 mol%, approximately 81 mol%, approximately 82 mol%, approximately 83 mol%, approximately 84 mol%, approximately 85 mol%, approximately 86 mol%, approximately 87 mol%, approximately 88 mol%, approximately 89 mol%, approximately 90 mol%, approximately 91%, approximately 92%, approximately 93%, approximately 94%, or approximately 95%.

[0095] In some embodiments, the proportion of structural units (c) in the water-compatible copolymer is less than 95 mol%, less than 90 mol%, less than 85 mol%, less than 80 mol%, less than 75 mol%, less than 70 mol%, less than 65 mol%, less than 60 mol%, less than 55 mol%, less than 50 mol%, less than 45 mol%, less than 40 mol%, less than 35 mol%, less than 30 mol%, less than 25 mol%, less than 20 mol%, or less than 15 mol%, based on the total number of moles of monomer units in the copolymer. In some embodiments, the proportion of structural units (c) in the water-compatible copolymer is greater than 5 mol%, greater than 10 mol%, greater than 15 mol%, greater than 20 mol%, greater than 25 mol%, greater than 30 mol%, greater than 35 mol%, greater than 40 mol%, greater than 45 mol%, greater than 50 mol%, greater than 55 mol%, greater than 60 mol%, greater than 65 mol%, greater than 70 mol%, greater than 75 mol%, greater than 80 mol%, or greater than 85 mol%, based on the total number of moles of monomer units in the copolymer.

[0096] In other embodiments, the water-compatible copolymer may further comprise structural units derived from olefins. Any hydrocarbon having at least one carbon-carbon double bond may be used as the olefin. In some embodiments, the olefin is C2-C 20 Aliphatic compounds, including vinyl unsaturated C8-C 20 Aromatic or cyclic compounds, C4-C 40This includes dienes and combinations thereof. In some embodiments, olefins are styrene, ethylene, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-tetradene, 1-hexadecene, 1-octadecene, 1-eicosene, 3-methyl-1-butene, cyclobutene, 3-methyl-1-pentene, 4-methyl-1-pentene, 4,6-dimethyl-1-heptene, 4-vinylcyclohexene, vinylcyclohexane, norbornene, norbornene, ethylidenenorbornene, cyclopentene, cyclohexene, dicyclopentadiene, cyclooctene, or combinations thereof. In some embodiments, the water-compatible copolymer does not contain structural units derived from olefins. In some embodiments, the water-compatible copolymer does not contain structural units derived from styrene, ethylene, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-tetradene, 1-hexadecene, 1-octadecene, 1-eicosene, 3-methyl-1-butene, cyclobutene, 3-methyl-1-pentene, 4-methyl-1-pentene, 4,6-dimethyl-1-heptene, 4-vinylcyclohexene, vinylcyclohexane, norbornene, norbornene, ethylidenenorbornene, cyclopentene, cyclohexene, dicyclopentadiene, or cyclooctene.

[0097] Conjugated dienes constitute olefins. In some embodiments, the conjugated diene is C4-C 40 Dienes are selected from the group consisting of: aliphatic conjugated dienes such as 1,3-butadiene, 1,3-pentadiene, 1,4-hexadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, isoprene, myrcene, 2-methyl-1,3-butadiene, 2,3-dimethyl-1,3-butadiene, and 2-chlor-1,3-butadiene; substituted linear conjugated pentadienes; substituted branched conjugated hexadienes; and combinations thereof. In some embodiments, the water-compatible copolymer is C4-C 40It does not contain structural units derived from dienes; aliphatic conjugated dienes (especially 1,3-butadiene, 1,3-pentadiene, 1,4-hexadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadien, isoprene, myrcene, 2-methyl-1,3-butadiene, 2,3-dimethyl-1,3-butadiene, or 2-chloro-1,3-butadiene); substituted linear conjugated pentadienes; or substituted branched conjugated hexadienes.

[0098] In other embodiments, the water-compatible copolymer may further contain structural units derived from aromatic vinyl group-containing monomers. In some embodiments, the aromatic vinyl group-containing monomer is styrene, α-methylstyrene, vinyltoluene, divinylbenzene, or a combination thereof. In some embodiments, the copolymer does not contain structural units derived from aromatic vinyl group-containing monomers. In some embodiments, the copolymer does not contain structural units derived from styrene, α-methylstyrene, vinyltoluene, or divinylbenzene.

[0099] Copolymers having the aforementioned structural unit ratios possess excellent binder properties. Furthermore, such copolymers are water-compatible and disperse well in aqueous solvents, making them easy to process when used in aqueous electrode slurries. Moreover, batteries using this water-soluble copolymer as electrodes exhibit excellent capacity and electrochemical performance.

[0100] After the polymerization process, a post-reaction mixture is formed. This post-reaction mixture mainly consists of the aqueous medium used in the polymerization process and a solid portion. In some embodiments, the solid portion of the post-reaction mixture contains a water-compatible copolymer.

[0101] In some processes, the solid portion of the post-reaction mixture is approximately 1% to 20% by weight, approximately 2% to 20% by weight, approximately 3% to 20% by weight, approximately 4% to 20% by weight, approximately 5% to 20% by weight, approximately 6% to 20% by weight, approximately 7% to 20% by weight, approximately 8% to 20% by weight, approximately 9% to 20% by weight, approximately 10% to 20% by weight, approximately 1% to 18% by weight, approximately 2% to 18% by weight, approximately 3% to 18% by weight, approximately 4% to 18% by weight, and approximately 5% by weight. From approximately 18% by weight, from approximately 6% to approximately 18% by weight, from approximately 7% to approximately 18% by weight, from approximately 8% to approximately 18% by weight, from approximately 9% to approximately 18% by weight, from approximately 10% to approximately 18% by weight, from approximately 1% to approximately 15% by weight, from approximately 2% to approximately 15% by weight, from approximately 3% to approximately 15% by weight, from approximately 4% to approximately 15% by weight, from approximately 5% to approximately 15% by weight, from approximately 6% to approximately 15% by weight, from approximately 7% to approximately 15% by weight, from approximately 8% to approximately 15% by weight, from approximately 1% to approximately 12% by weight, from approximately 2% to approximately 12% by weight, from approximately 3% to approximately 12% by weight, and from approximately 4% to approximately 15% by weight. The amounts are approximately 5% to 12% by weight, 1% to 10% by weight, 2% to 10% by weight, 3% to 10% by weight, 4% to 10% by weight, or 5% to 10% by weight.

[0102] In some embodiments, the solid content of the post-reaction mixture is less than 20% by weight, less than 19% by weight, less than 18% by weight, less than 17% by weight, less than 16% by weight, less than 15% by weight, less than 14% by weight, less than 13% by weight, less than 12% by weight, less than 11% by weight, less than 10% by weight, less than 9% by weight, less than 8% by weight, less than 7% by weight, less than 6% by weight, or less than 5% by weight, based on the total weight of the post-reaction mixture. In some embodiments, the solid content of the post-reaction mixture is more than 1% by weight, more than 2% by weight, more than 3% by weight, more than 4% by weight, more than 5% by weight, more than 6% by weight, more than 7% by weight, more than 8% by weight, more than 9% by weight, more than 10% by weight, more than 11% by weight, more than 12% by weight, more than 13% by weight, more than 14% by weight, or more than 15% by weight, based on the total weight of the post-reaction mixture.

[0103] When the weight-average molecular weight of the water-compatible copolymer is within the range shown below, the electrode layer made of the copolymer has good adhesive strength, and the battery made of such an electrode layer exhibits good cycle characteristics.

[0104] In some embodiments, the weight-average molecular weight of the water-compatible copolymer is approximately 10,000 g / mol to approximately 1,000,000 g / mol, approximately 10,000 g / mol to approximately 800,000 g / mol, approximately 10,000 g / mol to approximately 500,000 g / mol, approximately 10,000 g / mol to approximately 400,000 g / mol, approximately 10,000 g / mol to approximately 300,000 g / mol, approximately 10,000 g / mol to approximately 200,000 g / mol, approximately 10,000 g / mol to approximately 180,000 g / mol, approximately 10,000 g / mol to approximately 150,000 g / mol, and approximately 10,000 From g / mol to approximately 120,000 g / mol, from approximately 10,000 g / mol to approximately 100,000 g / mol, from approximately 10,000 g / mol to approximately 80,000 g / mol, from approximately 10,000 g / mol to approximately 50,000 g / mol, from approximately 50,000 g / mol to approximately 1,000,000 g / mol, from approximately 50,000 g / mol to approximately 800,000 g / mol, from approximately 50,000 g / mol to approximately 500,000 g / mol, from approximately 50,000 g / mol to approximately 400,000 g / mol, from approximately 50,000 g / mol to approximately 300,000 g / mol, and from approximately 50,000 g / mol to approximately 200,000 g / mol, approximately 50,000 g / mol to approximately 180,000 g / mol, approximately 50,000 g / mol to approximately 150,000 g / mol, approximately 100,000 g / mol to approximately 1,000,000 g / mol, approximately 100,000 g / mol to approximately 800,000 g / mol, approximately 100,000 g / mol to approximately 500,000 g / mol, approximately 100,000 g / mol to approximately 400,000 g / mol, approximately 100,000 g / mol to approximately 300,000 g / mol, approximately 100,000 g / mol to approximately 200,000 g / mol, approximately 100,000 g / mol to approximately 180,000 g / mol, approximately From 100,000 g / mol to approximately 150,000 g / mol, from approximately 120,000 g / mol to approximately 1,000,000 g / mol, from approximately 120,000 g / mol to approximately 800,000 g / mol, from approximately 120,000 g / mol to approximately 600,000 g / mol, from approximately 120,000 g / mol to approximately 500,000 g / mol, from approximately 120,000 g / mol to approximately 400,000 g / mol, from approximately 120,000 g / mol to approximately 300,000 g / mol, from approximately 120,000 g / mol to approximately 200,000 g / mol, from approximately 120,000 g / mol to approximately 190,000 g / mol, approximately 120,From 000g / mol to approximately 180,000g, from approximately 140,000g / mol to approximately 1,000,000g / mol, from approximately 140,000g / mol to approximately 800,000g / mol, from approximately 140,000g / mol to approximately 500,000g / mol, from approximately 140,000g / mol to approximately 400,000g / mol, from approximately 140,000g / mol to approximately 300,000g / mol, from approximately 140,000g / mol 200,000 g / mol, approximately 140,000 g / mol to 190,000 g / mol, approximately 140,000 g / mol to approximately 180,000 g / mol, approximately 150,000 g / mol to approximately 1,000,000 g / mol, approximately 150,000 g / mol to approximately 800,000 g / mol, approximately 150,000 g / mol to approximately 500,000 g / mol, approximately 150,000 g / mol to approximately 400,000 g / mol, approximately 150,000 g / mol to approximately 300,000 g / mol, approximately 150,000 g / mol to approximately 200,000 g / mol, approximately 150,000 g / mol to approximately 190,000 g / mol, approximately 150,000 g / mol to approximately 180,000 g / mol, approximately 200,000 g / mol to approximately 1,000,000 g / mol, approximately 200,000 g / mol to approximately 800,000 g / mol, The ranges are approximately 200,000 g / mol to 600,000 g / mol, 200,000 g / mol to 500,000 g / mol, 200,000 g / mol to 400,000 g / mol, 500,000 g / mol to 1,000,000 g / mol, 500,000 g / mol to 900,000 g / mol, or 500,000 g / mol to 800,000 g / mol.

[0105] In some embodiments, the weight-average molecular weight of the water-compatible copolymer is less than 1,000,000 g / mol, less than 800,000 g / mol, less than 600,000 g / mol, less than 500,000 g / mol, less than 400,000 g / mol, less than 300,000 g / mol, less than 200,000 g / mol, less than 190,000 g / mol, less than 180,000 g / mol, and less than 170,000 g / mol. The ranges are less than 160,000 g / mol, less than 150,000 g / mol, less than 140,000 g / mol, less than 130,000 g / mol, less than 120,000 g / mol, less than 110,000 g / mol, less than 100,000 g / mol, less than 90,000 g / mol, less than 80,000 g / mol, less than 70,000 g / mol, less than 60,000 g / mol, or less than 50,000 g / mol. In some embodiments, the weight-average molecular weight of the water-compatible copolymer is greater than 10,000 g / mol, greater than 20,000 g / mol, greater than 30,000 g / mol, greater than 40,000 g / mol, greater than 50,000 g / mol, greater than 60,000 g / mol, greater than 70,000 g / mol, greater than 80,000 g / mol, greater than 90,000 g / mol, greater than 100,000 g / mol, greater than 110,000 g / mol, greater than 120,000 g / mol More than 130,000 g / mol, more than 140,000 g / mol, more than 150,000 g / mol, more than 160,000 g / mol, more than 170,000 g / mol, more than 180,000 g / mol, more than 190,000 g / mol, more than 200,000 g / mol, more than 300,000 g / mol, more than 400,000 g / mol, more than 500,000 g / mol, more than 600,000 g / mol or more than 700,000 g / mol.

[0106] In some embodiments, the number-average molecular weight of the water-compatible copolymer is approximately 10,000 g / mol to approximately 500,000 g / mol, approximately 10,000 g / mol to approximately 300,000 g / mol, approximately 10,000 g / mol to approximately 200,000 g / mol, approximately 10,000 g / mol to approximately 100,000 g / mol, approximately 10,000 g / mol to approximately 90,000 g / mol, approximately 10,000 g / mol to approximately 80,000 g / mol, approximately 10,000 g / mol to approximately 70,000 g / mol, approximately 10,000 g / mol to approximately 60,000 g / mol, and approximately 10,000 g / mol to approximately 50,000 g / mol, approximately 10,000 g / mol to approximately 40,000 g / mol, approximately 20,000 g / mol to approximately 500,000 g / mol, approximately 20,000 g / mol to approximately 300,000 g / mol, approximately 20,000 g / mol to approximately 200,000 g / mol, approximately 20,000 g / mol to approximately 100,000 g / mol, approximately 20,000 g / mol to approximately 90,000 g / mol, approximately 20,000 g / mol to approximately 80,000 g / mol, approximately 20,000 g / mol to approximately 70,000 g / mol, approximately 20,000 g / mol to approximately 60,000 g / mol, approximately 20,000 g From 1 mole to approximately 50,000 g / mol, from approximately 30,000 g / mol to approximately 500,000 g / mol, from approximately 30,000 g / mol to approximately 300,000 g / mol, from approximately 30,000 g / mol to approximately 200,000 g / mol, from approximately 30,000 g / mol to approximately 100,000 g / mol, from approximately 30,000 g / mol to approximately 90,000 g / mol, from approximately 30,000 g / mol to approximately 80,000 g / mol, from approximately 30,000 g / mol to approximately 70,000 g / mol, from approximately 40,000 g / mol to approximately 500,000 g / mol, from approximately 40,000 g / mol to approximately 300,000 g / mol, From approximately 40,000 g / mol to approximately 200,000 g / mol, from approximately 40,000 g / mol to approximately 100,000 g / mol, from approximately 40,000 g / mol to approximately 90,000 g / mol, from approximately 40,000 g / mol to approximately 80,000 g / mol, from approximately 40,000 g / mol to approximately 70,000 g / mol, from approximately 50,000 g / mol to approximately 500,000 g / mol, from approximately 50,000 g / mol to approximately 300,000 g / mol, from approximately 50,000 g / mol to approximately 200,000 g / mol, from approximately 50,000 g / mol to approximately 100,000 g / mol, from approximately 50,000 g / mol to approximately 90,000g / mol, approximately 50,000g / mol to approximately 80,000g / mol, approximately 60,000g / mol to approximately 500,000g / mol, approximately 60,000g / mol to approximately 300,000g / mol, approximately 60,000g / mol to approximately 200,000g / mol, approximately 60,000g / mol to approximately 150,000g / mol, approximately 60,000g / mol to approximately 100 0,000g / mol, approximately 60,000g / mol to approximately 90,000g / mol, approximately 70,000g / mol to approximately 500,000g / mol, approximately 70,000g / mol to approximately 300,000g / mol, approximately 70,000g / mol to approximately 200,000g / mol, approximately 70,000g / mol to approximately 150,000g / mol, approximately 70,000g / mol to approximately 10 0,000 g / mol, approximately 80,000 g / mol to approximately 500,000 g / mol, approximately 80,000 g / mol to approximately 300,000 g / mol, approximately 80,000 g / mol to approximately 200,000 g / mol, approximately 80,000 g / mol to approximately 150,000 g / mol, approximately 90,000 g / mol to approximately 500,000 g / mol, approximately 90,000 g / mol to approximately The ranges are 300,000 g / mol, approximately 90,000 g / mol to approximately 200,000 g / mol, approximately 90,000 g / mol to approximately 150,000 g / mol, approximately 100,000 g / mol to approximately 500,000 g / mol, approximately 100,000 g / mol to approximately 300,000 g / mol, or approximately 100,000 g / mol to approximately 200,000 g / mol.

[0107] In some embodiments, the number-average molecular weight of the water-compatible copolymer is less than 500,000 g / mol, less than 400,000 g / mol, less than 300,000 g / mol, less than 200,000 g / mol, less than 150,000 g / mol, less than 100,000 g / mol, less than 90,000 g / mol, less than 80,000 g / mol, less than 70,000 g / mol, less than 60,000 g / mol, less than 50,000 g / mol, less than 45,000 g / mol, or less than 40,000 g / mol. In some embodiments, the number-average molecular weight of the water-compatible copolymer is greater than 10,000 g / mol, greater than 20,000 g / mol, greater than 30,000 g / mol, greater than 40,000 g / mol, greater than 45,000 g / mol, greater than 50,000 g / mol, greater than 60,000 g / mol, greater than 70,000 g / mol, greater than 80,000 g / mol, greater than 90,000 g / mol, greater than 100,000 g / mol, greater than 150,000 g / mol, greater than 200,000 g / mol, greater than 300,000 g / mol, or greater than 400,000 g / mol.

[0108] In some embodiments, the polydispersity index (PDI) of the water-compatible copolymer is approximately 1 to approximately 20, approximately 1 to approximately 15, approximately 1 to approximately 10, approximately 1 to approximately 5, approximately 1 to approximately 4.8, approximately 1 to approximately 4.2, approximately 1 to approximately 4, approximately 1 to approximately 3.8, approximately 1 to approximately 3.5, approximately 1 to approximately 3.2, approximately 1.2 to approximately 20, approximately 1.2 to approximately 15, approximately 1.2 to approximately 10, approximately 1.2 to approximately 5, approximately 1.2 to approximately 4.8, approximately 1.2 to approximately 4.5, approximately 1.2 to approximately 4.2, approximately 1.2 to approximately 3.8, approximately 1.2 to approximately 3.6, and approximately 1.2 to approximately 3.4, approximately 1.2 to approximately 3.2, approximately 1.2 to approximately 3, approximately 1.4 to approximately 20, approximately 1.4 to approximately 15, approximately 1.4 to approximately 10, approximately 1.4 to approximately 5, approximately 1.4 to approximately 4.8, approximately 1.4 to approximately 4.5, approximately 1.4 to approximately 4.2, approximately 1.4 to approximately 4, approximately 1.4 to approximately 3.8, approximately 1.4 to approximately 3.5, approximately 1.4 to approximately 3.2, approximately 1.4 to approximately 3, approximately 1.6 to approximately 20, approximately 1.6 to approximately 15, approximately 1. 6 to approximately 10, approximately 1.6 to approximately 5, approximately 1.6 to approximately 4.8, approximately 1.6 to approximately 4.5, approximately 1.6 to approximately 4, approximately 1.6 to approximately 3.8, approximately 1.6 to approximately 3.5, approximately 1.8 to approximately 20, approximately 1.8 to approximately 15, approximately 1.8 to approximately 10, approximately 1.8 to approximately 5, approximately 1.8 to approximately 4.8, approximately 1.8 to approximately 4.5, approximately 1.8 to approximately 4, approximately 1.8 to approximately 3.8, approximately 1.8 to approximately 3.5, approximately 2 to approximately 20, approximately 2 to approximately 15, approximately 2 to approximately 10, approximately 2 From approximately 5, from approximately 2 to approximately 4.5, from approximately 2 to approximately 4.2, from approximately 2 to approximately 4, from approximately 2 to approximately 3.8, from approximately 2 to approximately 3.5, from approximately 2.5 to approximately 20, from approximately 2.5 to approximately 15, from approximately 2.5 to approximately 10, from approximately 2.5 to approximately 5, from approximately 2.5 to approximately 4.8, from approximately 2.5 to approximately 4.5, from approximately 2.5 to approximately 4.2, from approximately 2.5 to approximately 4, from approximately 3 to approximately 20, from approximately 3 to approximately 15, from approximately 3 to approximately 10, from approximately 3 to approximately 5, from approximately 3 to approximately 4.8, from approximately 3 to approximately 4.6, or from approximately 3 to approximately 4.5.

[0109] In some embodiments, the polydispersity index of the water-compatible copolymer is less than 20, less than 15, less than 10, less than 5, less than 4.8, less than 4.5, less than 4.2, less than 4, less than 3.8, less than 3.5, less than 3.2, less than 3, less than 2.8, less than 2.5, less than 2.2, less than 2, less than 1.8, or less than 1.5. In some embodiments, the polydispersity index of the water-compatible copolymer is greater than 1, greater than 1.2, greater than 1.5, greater than 1.8, greater than 2, greater than 2.2, greater than 2.5, greater than 2.8, greater than 3, greater than 3.2, greater than 3.5, greater than 3.8, greater than 4, greater than 4.2, greater than 4.5, greater than 4.8, greater than 5, greater than 10, or greater than 15.

[0110] When the polydispersity index of the water-compatible copolymer is within the above range, each molecule of the copolymer has a similar weight, allowing the copolymer to be dispersed more uniformly in the dry electrode mixture or electrode slurry.

[0111] In conventional methods for preparing aqueous binder compositions, the post-reaction mixture obtained after polymerization becomes a wet binder composition. This wet binder composition is the final product and is used directly in electrode slurries. However, wet binder compositions consist of a large amount of aqueous medium. In some cases, the liquid content of a wet binder composition can exceed 80% of its total weight. While such a high liquid content allows for excellent dispersion of water-compatible copolymers, it makes the storage and transport of the binder composition highly inefficient. Therefore, binder compositions with reduced liquid content are desirable.

[0112] Therefore, in some embodiments, the post-reaction mixture is dried to remove the liquid, forming a binder composition with a reduced liquid content. In some embodiments, the dried binder composition is formed by drying the post-reaction mixture until substantially no liquid remains. In certain embodiments, the dried binder composition is formed by drying the post-reaction mixture until all liquid is completely gone.

[0113] In some embodiments, the liquid content of the dry binder composition is less than 1% by weight, less than 0.8% by weight, less than 0.6% by weight, less than 0.5% by weight, less than 0.4% by weight, less than 0.3% by weight, less than 0.25% by weight, less than 0.2% by weight, less than 0.15% by weight, less than 0.1% by weight, less than 0.05% by weight, less than 0.04% by weight, less than 0.03% by weight, less than 0.025% by weight, less than 0.01% by weight, less than 0.008% by weight, less than 0.005% by weight, less than 0.003% by weight, less than 0.002% by weight, or less than 0.001% by weight, based on the total weight of the dry binder composition.

[0114] The dryer used is not particularly limited, except that it is capable of reducing the liquid content of the post-reaction mixture without decomposing the copolymer in the mixture. In some embodiments, the dryer is a spray dryer, freeze dryer, pan dryer, rotary dryer, screw dryer, fluidized bed dryer, drum dryer, vacuum dryer, or a combination thereof.

[0115] In some embodiments, the dry binder composition is in the form of particles. In some embodiments, the particle size D50 of the dry binder composition particles is approximately 10 μm to approximately 50 μm, approximately 12 μm to approximately 50 μm, approximately 14 μm to approximately 50 μm, approximately 16 μm to approximately 50 μm, approximately 18 μm to approximately 50 μm, approximately 20 μm to approximately 50 μm, approximately 20 μm to approximately 48 μm, approximately 20 μm to approximately 46 μm, approximately 20 μm to approximately 44 μm, approximately 20 μm to approximately 42 μm, approximately 20 μm to approximately 40 μm, approximately 22 μm to approximately 40 μm, approximately 22 μm to approximately 38 μm, approximately 24 μm to approximately 38 μm, approximately 24 μm to approximately 36 μm, approximately 26 μm to approximately 34 μm, approximately 28 μm to approximately 34 μm, or approximately 28 μm to approximately 32 μm.

[0116] In some embodiments, the particle size D50 of the dried binder composition particles is less than 50 μm, less than 48 μm, less than 46 μm, less than 44 μm, less than 42 μm, less than 40 μm, less than 38 μm, less than 36 μm, less than 34 μm, less than 32 μm, less than 30 μm, less than 28 μm, less than 26 μm, less than 24 μm, less than 22 μm, less than 20 μm, less than 18 μm, less than 16 μm, less than 14 μm, or less than 12 μm. In some embodiments, the particle size D50 of the dried binder composition particles is greater than 10 μm, greater than 12 μm, greater than 14 μm, greater than 16 μm, greater than 18 μm, greater than 20 μm, greater than 22 μm, greater than 24 μm, greater than 26 μm, greater than 28 μm, greater than 30 μm, greater than 32 μm, greater than 34 μm, greater than 36 μm, greater than 38 μm, greater than 40 μm, greater than 42 μm, greater than 44 μm, greater than 46 μm, or greater than 48 μm.

[0117] By drying the binder composition until virtually no liquid remains, the remaining liquid in the dried binder composition occupies a negligible mass and volume, thus achieving maximum efficiency in storage and transport. The dried binder composition can be used to produce a dry electrode mixture or electrode slurry, which can then be applied onto a current collector to form electrodes.

[0118] In other embodiments, the binder composition is a semi-dried binder composition. In some embodiments, the semi-dried binder composition is obtained by directly drying the post-reaction mixture to a desired solid content. In such cases, the semi-dried binder composition will have the same aqueous medium as, or derived from, the aqueous solvent in the polymerization process. In other embodiments, to more precisely control the liquid content of the binder composition, the semi-dried binder composition is obtained by partially rehydrating the dried binder composition disclosed above.

[0119] In some embodiments, an aqueous solvent is added to the dry binder composition to rehydrate it into a semi-dry binder composition. Any aqueous solvent suitable as the aqueous medium for the polymerization process is also suitable for rehydrating the dry binder composition into a semi-dry binder composition. In some embodiments, the aqueous solvent used to rehydrate the dry binder composition and the aqueous medium for the polymerization process have the same composition. In other embodiments, the aqueous solvent used to rehydrate the dry binder composition and the aqueous medium for the polymerization process have different compositions.

[0120] In other embodiments, to rehydrate a dry binder composition into a semi-dry binder composition, the dry binder composition is placed in a humid environment to absorb moisture from the humid environment. This moisture then acts as an aqueous solvent for rehydration. In some embodiments, the binder composition is stirred while being rehydrated so that the entire binder composition can be rehydrated by the humid environment. There are no particular restrictions on the stirring speed of the binder composition during water replenishment, but the stirring speed should be fast enough to facilitate the complete replenishment of the binder composition. In other embodiments, the binder composition is not stirred while being rehydrated.

[0121] In some embodiments, the humid environment is a controlled environment. In some embodiments, the controlled environment is a glove box. In some embodiments, the controlled environment is an incubator. In some embodiments, the controlled environment is room temperature. In other embodiments, the humid environment can refer to an open environment if the humidity of the open environment is sufficiently high.

[0122] There are no particular restrictions on the humidity of the humid environment, except that the specific humidity of the humid environment should be greater than the liquid content of the dry binder composition in order to ensure that the dry binder composition absorbs moisture from the humid environment to form a semi-dry binder composition. In some embodiments, the specific humidity of the humid environment is greater than 0.1 g / kg, greater than 0.15 g / kg, greater than 0.2 g / kg, greater than 0.25 g / kg, greater than 0.5 g / kg, greater than 1 g / kg, greater than 1 g / kg, greater than 1 g / kg, greater than 1 g / kg, greater than 2 g / kg, greater than 3 g / kg, greater than 4 g / kg, greater than 5 g / kg, greater than 6 g / kg, greater than 8 g / kg, greater than 10 g / kg, greater than 12.5 g / kg, greater than 15 g / kg, greater than 20 g / kg, greater than 30 g / kg, greater than 40 g / kg, greater than 50 g / kg, greater than 75 g / kg, or greater than 100 g / kg.

[0123] The period for which the dry binder composition is left in a humid environment is not particularly limited, except that it should be long enough for the dry binder composition to absorb moisture from the humid environment and form a semi-dried binder composition. In some embodiments, the dry binder composition is left in a humid environment for 5 minutes, 15 minutes, 30 minutes, 45 minutes, 60 minutes, 2 hours, 4 hours, 6 hours, 12 hours, 1 day, 2 days, 3 days, 1 week, or 2 weeks.

[0124] In some embodiments, the liquid content of the semi-dried binder composition is, based on the total weight of the semi-dried binder composition, about 1% to about 85% by weight, about 1% to about 80% by weight, about 1% to about 75% by weight, about 1% to about 70% by weight, about 1% to about 65% by weight, about 1% to about 60% by weight, about 1% to about 55% by weight, about 1% to about 50% by weight, about 1% to about 45% by weight, about 1% to about 40% by weight, and about 1% to about 35% by weight. Approximately 1 to approximately 30% by weight, approximately 1% to approximately 25% by weight, approximately 1% to approximately 20% by weight, approximately 10% to approximately 85% by weight, approximately 10% to approximately 80% by weight, approximately 10% to approximately 75% by weight, approximately 10% to approximately 70% by weight, approximately 10% to approximately 65% ​​by weight, approximately 10% to approximately 60% by weight, approximately 10% to approximately 55% by weight, approximately 10% to approximately 50% by weight, approximately 10% to approximately 45% by weight, approximately 10% to approximately 40% by weight, approximately 10% to approximately 3 5% by weight, approximately 10% to approximately 30% by weight, approximately 10% to approximately 25% by weight, approximately 20% to approximately 85% by weight, approximately 20% to approximately 80% by weight, approximately 20% to approximately 75% by weight, approximately 20% to approximately 70% by weight, approximately 20% to approximately 65% ​​by weight, approximately 20% to approximately 60% by weight, approximately 20% to approximately 55% by weight, approximately 20% to approximately 50% by weight, approximately 20% to approximately 45% by weight, approximately 20% to approximately 40% by weight, approximately 30% to 85% by weight, The weights are approximately 30% to 80%, 30% to 75%, 30% to 70%, 30% to 65%, 30% to 60%, 30% to 55%, 30% to 50%, 40% to 85%, 40% to 80%, 40% to 75%, 40% to 70%, 40% to 65%, or 40% to 60%.

[0125] In some embodiments, the liquid content of the semi-dried binder composition is approximately 1% by weight, approximately 2% by weight, approximately 3% by weight, approximately 4% by weight, approximately 5% by weight, approximately 6% by weight, approximately 7% by weight, approximately 8% by weight, approximately 9% by weight, approximately 10% by weight, approximately 11% by weight, approximately 12% by weight, approximately 13% by weight, approximately 14% by weight, approximately 15% by weight, approximately 16% by weight, and approximately 17% by weight, based on the total weight of the semi-dried binder composition. , about 18% by weight.about 19% by weight, about 20% by weight, about 21% by weight, about 22% by weight, about 23% by weight, about 24% by weight, about 25% by weight, about 26% by weight, about 27% by weight, about 28% by weight, about 2 9% by weight, approximately 30% by weight, approximately 31% by weight, approximately 32% by weight, approximately 33% by weight, approximately 34% by weight, approximately 35% by weight, approximately 36% by weight, approximately 37% by weight, approximately 38% by weight, approximately 39% by weight, approximately 40% by weight , about 41% by weight, about 42% by weight, about 43% by weight, about 44% by weight, about 45% by weight, about 46% by weight, about 47% by weight, about 48% by weight, about 49% by weight, about 50% by weight, about 51% by weight, about 5 2% by weight, approximately 53% by weight, approximately 54% by weight, approximately 55% by weight, approximately 56% by weight, approximately 57% by weight, approximately 58% by weight, approximately 59% by weight, approximately 60% by weight, approximately 61% by weight, approximately 62% by weight, approximately 63% by weight The weights are approximately 64% by weight, 65% by weight, 66% by weight, 67% by weight, 68% by weight, 69% by weight, 70% by weight, 71% by weight, 72% by weight, 73% by weight, 74% by weight, 75% by weight, 76% by weight, 77% by weight, 78% by weight, 79% by weight, 80% by weight, 81% by weight, 82% by weight, 83% by weight, 84% by weight, or 85% by weight.

[0126] In some embodiments, the liquid content of the semi-dried binder composition is less than 85% by weight, less than 80% by weight, less than 75% by weight, less than 70% by weight, less than 65% by weight, less than 60% by weight, less than 55% by weight, less than 50% by weight, less than 45% by weight, less than 40% by weight, less than 35% by weight, less than 30% by weight, less than 25% by weight, less than 20% by weight, less than 15% by weight, or less than 10% by weight, based on the total weight of the semi-dried binder composition. In some embodiments, the liquid content of the semi-dried binder composition is greater than 1% by weight, greater than 5% by weight, greater than 10% by weight, greater than 15% by weight, greater than 20% by weight, greater than 25% by weight, greater than 30% by weight, greater than 35% by weight, greater than 40% by weight, greater than 45% by weight, greater than 50% by weight, greater than 55% by weight, greater than 60% by weight, greater than 65% by weight, greater than 70% by weight, or greater than 75% by weight, based on the total weight of the semi-dried binder composition.

[0127] While a low liquid content in dry binder compositions helps improve logistics efficiency, it is not always best to minimize the liquid content of the binder composition as much as possible. Aqueous solvents in semi-dry binder compositions can reduce the risk of powder explosion and minimize the effects of static electricity. Electrode slurry can be prepared using a semi-dry binder composition and applied to a current collector to form electrodes.

[0128] In some embodiments, the dry electrode mixture or electrode slurry contains an electrode active material, separate from the binder composition. Such an electrode active material may be a positive electrode active material or a negative electrode active material. When the dry electrode mixture or electrode slurry contains a positive electrode active material, the dry electrode mixture or electrode slurry may be referred to as a positive electrode mixture and a positive electrode slurry, respectively. When the dry electrode mixture or electrode slurry consists of a negative electrode active material, the dry electrode mixture or electrode slurry may be referred to as a negative electrode mixture and a negative electrode slurry, respectively. In some embodiments, the dry electrode mixture or electrode slurry further contains a conductive agent.

[0129] Many positive electrode active materials are unstable in water and can react with water to form unwanted impurities such as lithium hydroxide (LiOH). The presence of such impurities degrades the electrochemical performance of the battery. As a method to waterproof such positive electrode active materials, methods such as coating the positive electrode active material to form a core-shell type positive electrode active material have been devised. However, these methods increase manufacturing costs and time, and may even adversely affect battery performance. Therefore, by forming electrodes using a dry electrode mixture, it is possible to prevent the degradation of the positive electrode active material due to reaction with water.

[0130] The dry electrode mixture can be prepared using the dry binder composition disclosed herein, and no solvent is added in the preparation of the dry electrode mixture. Thus, the dry electrode mixture will contain the electrode active material and the dry binder composition, and optionally a conductive agent, but will be substantially liquid-free or liquid-free.

[0131] In some embodiments, the liquid content of the dry electrode mixture is less than 1% by weight, less than 0.8% by weight, less than 0.6% by weight, less than 0.5% by weight, less than 0.4% by weight, less than 0.3% by weight, less than 0.25% by weight, less than 0.2% by weight, less than 0.15% by weight, less than 0.1% by weight, less than 0.05% by weight, less than 0.04% by weight, less than 0.03% by weight, less than 0.025% by weight, less than 0.01% by weight, less than 0.008% by weight, less than 0.005% by weight, less than 0.003% by weight, less than 0.002% by weight, or less than 0.001% by weight, based on the total weight of the dry electrode mixture.

[0132] Conversely, the electrode slurry contains a liquid. The electrode slurry can be prepared using the dry or semi-dried binder compositions disclosed herein. The liquid portion of the electrode slurry consists of an aqueous solvent such as water, and at least a portion of it may be derived from the aqueous solvent of the semi-dried binder composition.

[0133] Since the electrode slurry is a liquid, it can be easily applied to the current collector to form electrodes even without harsh conditions such as high temperature and high pressure. This improves the safety of the application process and reduces the cost of implementing safety measures during the application process. Furthermore, it reduces the risk of powder explosions, thus improving overall safety.

[0134] Furthermore, in electrode slurries with a relatively low liquid content of 30% or less of the total slurry weight, water is mainly embedded in polymer chains and is not directly exposed to other electrode components in the slurry. As a result, problems caused by the presence of water in the electrode slurry, such as the reaction of water with the positive electrode active material, can be reduced.

[0135] Therefore, in certain embodiments, the electrode slurry is prepared using a semi-dried binder composition to which no solvent is added during the preparation of the electrode slurry. In such cases, the liquid portion of the semi-dried binder composition, which consists of an aqueous solvent, is sufficient to provide the liquid portion of the electrode slurry. Thus, the electrode slurry comprises an electrode active material, a semi-dried binder composition, and optionally a conductive agent. In other embodiments, the electrode slurry is prepared using a dry or semi-dried binder composition disclosed herein, where an additional solvent is added during the preparation of the electrode slurry. The electrode slurry then comprises an electrode active material, a dry or semi-dried binder composition, an additional solvent, and optionally a conductive agent.

[0136] As disclosed above, both the dry electrode mixture and the electrode slurry have their own advantages. Therefore, the binder composition disclosed herein can be used as a binder composition for a dry electrode mixture or as a binder composition for an electrode slurry, depending on production needs.

[0137] The method used to produce a dry electrode mixture or electrode slurry is not particularly limited, except that all electrode components should be thoroughly mixed to form a homogeneous dry electrode mixture or electrode slurry, which can be achieved, for example, by using a homogenizer. In some embodiments, all materials used to produce the dry electrode mixture or electrode slurry are added to the homogenizer in a single batch. In other embodiments, each component of the dry electrode mixture or electrode slurry (e.g., electrode active material, binder composition, and any conductive agent) is added to the homogenizer in several batches, and each batch may consist of multiple electrode components.

[0138] In some embodiments, if an additional solvent is added to the electrode slurry, the additional solvent is an aqueous solvent. Any aqueous solvent suitable as an aqueous medium in the polymerization process and / or as an aqueous solvent in the rehydration of a dry binder composition to a semi-dried binder composition is also suitable as an additional solvent in the electrode slurry. In some embodiments, if an additional solvent is added in the preparation of the electrode slurry, the additional solvent may be added before, after, and / or during the homogenization of the electrode components in one or more batches.

[0139] In some embodiments, when an additional solvent is added to the electrode slurry, the additional solvent and the aqueous medium of the polymerization process have the same composition. In some embodiments, when an additional solvent is added to the electrode slurry, the additional solvent and the aqueous solvent used to rehydrate the dry binder composition to a semi-dry binder composition have the same composition. In some embodiments, when an additional solvent is added to the electrode slurry, the additional solvent, the aqueous medium of the polymerization process, and the aqueous solvent used to rehydrate the dry binder composition to a semi-dry binder composition all have the same composition. In other embodiments, when an additional solvent is added to the electrode slurry, two or more of the additional solvent, the aqueous medium of the polymerization process, and the aqueous solvent used to rehydrate the dry binder composition to a semi-dry binder composition have different compositions.

[0140] In other embodiments, the electrode slurry is formed by placing a dry electrode mixture in a humid environment and absorbing moisture from the humid environment. This moisture then acts as an additional solvent. When this method is used, the liquid content of the electrode slurry is considered to be relatively lower compared to the liquid content of conventional electrode slurries. In some embodiments, the humid environment is a controlled environment. In some embodiments, the controlled environment is a glove box. In some embodiments, the controlled environment is an incubator. In some embodiments, the controlled environment is room temperature. In other embodiments, the humid environment can refer to an open environment if the humidity of the open environment is sufficiently high.

[0141] The humidity of the humid environment is not particularly limited, but it is desirable that the specific humidity of the humid environment be greater than the liquid content of the dry electrode mixture in order to ensure that the dry electrode mixture absorbs moisture from the humid environment to form an electrode slurry. In some embodiments, the specific humidity of the humid environment is greater than 0.1 g / kg, greater than 0.15 g / kg, greater than 0.2 g / kg, greater than 0.25 g / kg, greater than 0.5 g / kg, greater than 1 g / kg, greater than 1.5 g / kg, greater than 2 g / kg, greater than 3 g / kg, greater than 4 g / kg, greater than 5 g / kg, greater than 6 g / kg, greater than 8 g / kg, greater than 10 g / kg, greater than 12.5 g / kg, greater than 15 g / kg, greater than 20 g / kg, greater than 30 g / kg, greater than 40 g / kg, greater than 50 g / kg, greater than 75 g / kg, or greater than 100 g / kg.

[0142] The duration for which the dry electrode mixture is left in a humid environment is not particularly limited, except that it is long enough for the dry electrode mixture to absorb moisture from the humid environment and form an electrode slurry. In some embodiments, the dry electrode mixture is left in a humid environment for periods of 5 minutes, 15 minutes, 30 minutes, 45 minutes, 60 minutes, 2 hours, 4 hours, 6 hours, 12 hours, 1 day, 2 days, 3 days, 1 week, or 2 weeks.

[0143] In some embodiments, the electrode active material is LiCoO2, LiNiO2, LiNi x Mn y O2, LiCo x Ni y O2, Li 1+z Ni x Mn y Co 1-x-y This is a positive electrode active material selected from the group consisting of O2(NMC). LiNi x Co y Al z O2(NCA), LiV2O5, LiTiS2, LiMoS2, LiMnO2, LiCrO2, LiMn2O4, Li2MnO3, LiFeO2, LiFePO4 and combinations thereof, where each x is independently from 0.1 to 0.9; each y is independently from 0 to 0.9; and each z is independently from 0 to 0.4. In some embodiments, each x, y, and z in the above general formula are independently spaced at 0.01 intervals. In other embodiments, the positive electrode active material is not LiCoO2, LiNiO2, LiV2O5, LiTiS2, LiMoS2, LiMnO2, LiCrO2, LiMn2O4, LiFeO2, or LiFePO4. In further embodiments, the positive electrode active material is LiNi x Mn y O2, Li 1+z Ni x Mn y Co 1-x-y O2, LiLiLi x Co y Al z O2 or LiCo x Ni yNot O2, where each x is independently from 0.1 to 0.9, each y is independently from 0 to 0.9, and each z is independently from 0 to 0.4. In certain embodiments, the positive electrode active material is Li 1+x Ni a Mn b Co c Al (1-a-b-c) O2; where - 0.2 ≦ x ≦ 0.2, 0 ≦ a < 1, 0 ≦ b < 1, 0 ≦ c < 1, and a + b + c ≦ 1. In some embodiments, the positive electrode active material has the general formula LiMPO4, and M is selected from the group consisting of Fe, Co, NI, Mn, Al, Mg, Zn, Ti, La, Ce, Sn, Zr, Ru, Si, Ge, or combinations thereof. In some embodiments, the positive electrode active material is selected from the group consisting of LiFePO4, LiCoPO4, LiNiPO4, LiMnPO4, LiMnFePO4, LiMn x Fe (1-x) PO4, and combinations thereof; where 0 < x < 1. In some embodiments, the positive electrode active material is LiNi x Mn y O4; where 0.1 ≦ x ≦ 0.9 and 0 ≦ y ≦ 2. In certain embodiments, the positive electrode active material is x Li2MnO3·(1 - x)LiMO2, where M is selected from the group consisting of Ni, Co, Mn, and combinations thereof; and 0 < x < 1. In some embodiments, the positive electrode active material is Li3V2(PO4)3, or LiVPO4F. In certain embodiments, the positive electrode active material has the general formula Li2MSiO4, and M is selected from the group consisting of Fe, Co, Mn, Ni, and combinations thereof.

[0144] In certain embodiments, the positive electrode active material is doped with a dopant selected from the group consisting of Co, Cr, V, Mo, Nb, Pd, F, Na, Fe, Ni, Mn, Al, Mg, Zn, Ti, La, Ce, Sn, Zr, Ru, Si, Ge, and combinations thereof. In some embodiments, the dopant is not Co, Cr, V, Mo, Nb, Pd, F, Na, Fe, Ni, Mn, Mg, Zn, Ti, La, Ce, Ru, Si, or Ge. In certain embodiments, the dopant is not Al, Sn, or Zr.

[0145] In certain embodiments, the positive electrode active material consists of a core-shell composite having a core and shell structure, or is a core-shell composite. In some embodiments, the core consists of one or more lithium transition metal oxides. In some embodiments, the shell consists of one or more lithium transition metal oxides and / or one or more transition metal oxides. In some embodiments, the one or more lithium transition metal oxides are Li 1+x Ni a Mn b Co c Al (1-a-b-c) O2, LiCoO2, LiNiO2, LiMnO2, LiMn2O4, Li2MnO3, LiCrO2, Li4Ti5O 12 , LiV2O5, LiTiS2, LiMoS2, LiCo a Ni b O2, LiMn a Ni bThe transition metal oxides are selected from the group consisting of O2 and combinations thereof, where -0.2 ≤ x ≤ 0.2, 0 ≤ a < 1, 0 ≤ b < 1, 0 ≤ c < 1, and a + b + c ≤ 1. In some embodiments, each lithium transition metal oxide is independently doped with one or more dopants selected from the group consisting of Co, Cr, V, Mo, Nb, Pd, F, Na, Fe, Ni, Mn, Al, Mg, Zn, Ti, La, Ce, Sn, Zr, Ru, Si, Ge, and combinations thereof. In some embodiments, one or more transition metal oxides are selected from the group consisting of Fe2O3, MnO2, Al2O3, MgO, ZnO, TiO2, La2O3, CeO2, SnO2, ZrO2, RuO2, and combinations thereof.

[0146] In some embodiments, each of the shell and core consists of one or more lithium transition metal oxides. In some embodiments, the lithium transition metal oxides of the core and shell may be the same, different, or partially different. In some embodiments, if the core or shell consists of two or more lithium transition metal oxides, the two or more lithium transition metal oxides are uniformly distributed on the core or shell. In certain embodiments, if the core or shell consists of two or more lithium transition metal oxides, the two or more lithium transition metal oxides are not uniformly distributed on the core or shell. In some embodiments, the positive electrode active material is not a core-shell composite.

[0147] In certain embodiments, the shell thickness and core diameter are independently about 1 μm to about 45 μm, about 1 μm to about 25 μm, about 1 μm to about 15 μm, about 1 μm to about 5 μm, about 3 μm to about 15 μm, about 5 μm to about 10 μm, about 10 μm to about 35 μm, about 15 μm to about 30 μm, about 15 μm to about 25 μm, or about 20 μm to about 30 μm. In certain embodiments, the ratio of core to shell diameter or thickness is in the range of 15:85 to 85:15, 25:75 to 75:25, 30:70 to 70:30, or 40:60 to 60:40. In certain embodiments, the volume or weight ratio of the core to the shell is in the range of 95:5, 90:10, 80:20, 70:30, 60:40, 50:50, 40:60, or 30:70.

[0148] In some embodiments, the electrode active material is natural graphite nanoparticles, synthetic graphite nanoparticles, hard carbon, soft carbon, mesocarbon microbeads (MCMB), Sn nanoparticles, SnO2, SnO, Li4Ti5O 12 The negative electrode active material is selected from the group consisting of fine particles, Si fine particles, Si-C composite fine particles, and combinations thereof.

[0149] In certain embodiments, the negative electrode active material is doped with a dopant. In some embodiments, the dopant is selected from the group consisting of Fe, Ni, Mn, Al, Mg, Zn, Ti, La, Ce, Sn, Zr, Ru, and combinations thereof. In some embodiments, the dopant is B, Si, Ge, N, P, F, S, Cl, I, Se, or combinations thereof. In other embodiments, the negative electrode active material is not doped. In some embodiments, the negative electrode active material is not doped with Fe, Ni, Mn, Al, Mg, Zn, Ti, La, Ce, Sn, Zr, Ru, B, Si, Ge, N, P, F, S, Cl, I, or Se.

[0150] In some embodiments, the negative electrode active material consists of or is a core-shell composite having a core and shell structure. In some embodiments, the core is natural graphite nanoparticles, synthetic graphite nanoparticles, hard carbon, soft carbon, mesocarbon microbeads (MCMB), Sn nanoparticles, SnO2, SnO, Li4Ti5O 12 The shell is selected from the group consisting of fine particles, Si fine particles, Si-C composite fine particles, and combinations thereof. In some embodiments, the shell is made of soft carbon, hard carbon, natural graphite fine particles, synthetic graphite fine particles, mesocarbon microbeads (MCMB), quiche graphite, pyrolysis carbon, mesophase pitch, mesophase pitch-based carbon fibers, Sn fine particles, SnO2, SnO, Li4Ti5O 12 The group consists of fine particles, Si fine particles, Si-C composite fine particles, and combinations thereof.

[0151] In some embodiments, the dry electrode mixture or electrode slurry may further contain a conductive agent. The conductive agent enhances the electrical conductivity of the electrode. Therefore, it may be advantageous for the dry electrode mixture or electrode slurry to contain a conductive agent. Any suitable material can act as a conductive agent. In some embodiments, the conductive agent is a carbonaceous material. Some non-limiting examples include carbon, carbon black, graphite, expanded graphite, graphene, graphene nanoplatelets, carbon fibers, carbon nanofibers, graphitized carbon flakes, carbon tubes, carbon nanotubes, activated carbon, Super P, KS6, vapor-grown carbon fibers (VGCF), mesoporous carbon, and combinations thereof. In certain embodiments, the conductive agent does not contain a carbonaceous material.

[0152] In some embodiments, the conductive agent is a conductive polymer selected from the group consisting of polypyrrole, polyaniline, polyacetylene, polyphenylene sulfide (PPS), polyphenylene vinylene (PPV), poly(3,4-ethylenedioxythiophene) (PEDOT), polythiophene, and combinations thereof. In some embodiments, the conductive agent also acts as a binder composition. In some embodiments, the conductive agent is a mixture of a carbonaceous material and a conductive polymer. In other embodiments, the conductive agent does not contain a conductive polymer.

[0153] The dry electrode mixture or electrode slurry may contain additives as needed to obtain the desired electrode properties. In certain embodiments, the additive is a conductive polymer used in addition to the conductive agent. In some embodiments, the additive is a dispersant or surfactant to promote homogenization of the electrode mixture or slurry.

[0154] In some embodiments, the proportion of binder copolymer in the solid portion of the dry electrode mixture or electrode slurry is, based on the total weight of the solid portion of the dry electrode mixture or electrode slurry, about 1% to about 50% by weight, about 2% to about 50% by weight, about 5% to about 50% by weight, about 8% to about 50% by weight, about 10% to about 50% by weight, about 15% to about 50% by weight, about 20% to about 50% by weight, about 25% to about 50% by weight, about 30% to about 50% by weight, about 1% to about 40% by weight, about 2% to about 40% by weight, about 5% to about 40% by weight, about 8% to about 40% by weight, about 10% to about 40% by weight, about 15% to about 40% by weight, about 20% to about 40% by weight, about 25% to about 40% by weight, and about 30% to about 40% by weight. Approximately 1% to 30% by weight, approximately 2% to 30% by weight, approximately 5% to 30% by weight, approximately 8% to 30% by weight, approximately 10% to 30% by weight, approximately 15% to 30% by weight, approximately 20% to 30% by weight, approximately 1% to 20% by weight, approximately 2% to 20% by weight, approximately 5% to 20% by weight, approximately 8% to 20% by weight. Approximately 10% to 20% by weight, approximately 15% to 20% by weight, approximately 1% to 10% by weight, approximately 2% to 10% by weight, approximately 5% to 10% by weight, approximately 1% to 5% by weight, or approximately 2% to 5% by weight.

[0155] In some embodiments, the proportion of binder copolymer in the solid portion of the dry electrode mixture or electrode slurry is less than 50% by weight, less than 45% by weight, less than 40% by weight, less than 35% by weight, less than 30% by weight, less than 25% by weight, less than 20% by weight, less than 15% by weight, less than 10% by weight, less than 8% by weight, or less than 5% by weight, based on the total weight of the solid portion of the dry electrode mixture or electrode slurry. In some embodiments, the proportion of binder copolymer in the solid portion of the dry electrode mixture or electrode slurry is more than 1% by weight, more than 2% by weight, more than 5% by weight, more than 8% by weight, more than 10% by weight, more than 15% by weight, more than 20% by weight, more than 25% by weight, more than 30% by weight, more than 35% by weight, or more than 40% by weight, based on the total weight of the solid portion of the dry electrode mixture or electrode slurry.

[0156] In some embodiments, the proportion of conductive agent in the solid portion of the dry electrode mixture or electrode slurry is, respectively, about 1% to about 20% by weight, about 2% to about 20% by weight, about 5% to about 20% by weight, about 8% to about 20% by weight, about 10% to about 20% by weight, about 15% to about 20% by weight, about 1% to about 10% by weight, about 2% to about 10% by weight, about 5% to about 10% by weight, about 1% to about 5% by weight, or about 2% to about 5% by weight, based on the total weight of the solid portion of the dry electrode mixture or electrode slurry.

[0157] In some embodiments, the proportion of conductive agent in the solid portion of the dry electrode mixture or electrode slurry is less than 20% by weight, less than 15% by weight, less than 10% by weight, less than 8% by weight, or less than 5% by weight, based on the total weight of the solid portion of the dry electrode mixture or electrode slurry. In some embodiments, the proportion of conductive agent in the solid portion of the dry electrode mixture or electrode slurry is more than 1% by weight, more than 2% by weight, more than 5% by weight, more than 8% by weight, more than 10% by weight, or more than 15% by weight, based on the total weight of the solid portion of the dry electrode mixture or electrode slurry.

[0158] In some embodiments, the proportion of electrode active material in the solid portion of the dry electrode mixture or electrode slurry is, respectively, about 40% to about 99% by weight, about 45% to about 99% by weight, about 50% to about 99% by weight, about 55% to about 99% by weight, about 60% to about 99% by weight, about 65% to about 99% by weight, about 70% to about 99% by weight, about 75% to about 99% by weight, about 80% to about 99% by weight, about 40% to about 95% by weight, about 45% to about 95% by weight, about 50% to about 95% by weight, about 55% to about 95% by weight, about 60% to about 95% by weight, and about 65% to about 95% by weight. These are approximately 70% to 95% by weight, 75% to 95% by weight, 80% to 95% by weight, 40% to 90% by weight, 45% to 90% by weight, 50% to 90% by weight, 55% to 90% by weight, 60% to 90% by weight, 65% to 90% by weight, 70% to 90% by weight, 75% to 90% by weight, 80% to 90% by weight, 40% to 85% by weight, 45% to 85% by weight, 50% to 85% by weight, 55% to 85% by weight, 60% to 85% by weight, 65% to 85% by weight, 70% to 85% by weight, or 75% to 85% by weight.

[0159] In some embodiments, the proportion of electrode active material in the solid portion of the dry electrode mixture or electrode slurry is less than 99% by weight, less than 95% by weight, less than 90% by weight, less than 85% by weight, less than 80% by weight, less than 75% by weight, less than 70% by weight, less than 65% by weight, less than 60% by weight, less than 55% by weight, or less than 50% by weight, based on the total weight of the solid portion of the dry electrode mixture or electrode slurry. In some embodiments, the proportion of electrode active material in the solid portion of the dry electrode mixture or electrode slurry is more than 40% by weight, more than 45% by weight, more than 50% by weight, more than 55% by weight, more than 60% by weight, more than 65% by weight, more than 70% by weight, more than 75% by weight, more than 80% by weight, or more than 85% by weight, based on the total weight of the solid portion of the dry electrode mixture or electrode slurry.

[0160] In several formulations, the proportion of additional solvent added to the electrode slurry is based on the total weight of the slurry, ranging from approximately 0% to approximately 60% by weight, approximately 2% to approximately 60% by weight, approximately 5% to approximately 60% by weight, approximately 8% to approximately 60% by weight, approximately 10% to approximately 60% by weight, approximately 12% to approximately 60% by weight, approximately 15% to approximately 60% by weight, approximately 18% to approximately 60% by weight, approximately 20% to approximately 60% by weight, approximately 22% to approximately 60% by weight, approximately 25% to approximately 60% by weight, approximately 28% to approximately 60% by weight, approximately 30% to approximately 60% by weight, and approximately 32% From % to approximately 60% by weight, from approximately 35% to approximately 60% by weight, from approximately 38% to approximately 60% by weight, from approximately 40% to approximately 60% by weight, from approximately 42% to approximately 60% by weight, from approximately 45% to approximately 60% by weight, from approximately 0% to approximately 50% by weight, from approximately 2% to approximately 50% by weight, from approximately 5% to approximately 50% by weight, from approximately 8% to approximately 50% by weight, from approximately 10% to approximately 50% by weight, from approximately 12% to approximately 50% by weight, from approximately 15% to approximately 50% by weight, from approximately 18% to approximately 50% by weight, from approximately 20% to approximately 50% by weight, from approximately 22% to approximately 50% by weight, from approximately 25% to approximately 5 0% by weight, approximately 28% to approximately 50% by weight, approximately 30% to approximately 50% by weight, approximately 32% to approximately 50% by weight, approximately 35% to approximately 50% by weight, approximately 0% to approximately 40% by weight, approximately 2% to approximately 40% by weight, approximately 5% to approximately 40% by weight, approximately 8% to approximately 40% by weight, approximately 10% to approximately 40% by weight, approximately 12% to approximately 40% by weight, approximately 15% to approximately 40% by weight, approximately 18% to approximately 40% by weight, approximately 20% to approximately 40% by weight, approximately 22% to approximately 40% by weight, approximately 25% to approximately 40% by weight, approximately 28% to approximately 40% by weight, approximately 30% by weight From approximately 40% by weight, from approximately 0% to approximately 30% by weight, from approximately 2% to approximately 30% by weight, from approximately 8% to approximately 30% by weight, from approximately 10% to approximately 30% by weight, from approximately 12% to approximately 30% by weight, from approximately 15% to approximately 30% by weight, from approximately 18% to approximately 30% by weight, from approximately 20% to approximately 30% by weight, from approximately 0% to approximately 20% by weight, from approximately 2% to approximately 20% by weight, from approximately 5% to approximately 20% by weight, from approximately 8% to approximately 20% by weight, from approximately 10% to approximately 20% by weight, from approximately 0% to approximately 15% by weight, from approximately 3% to approximately 15% by weight, or from approximately 5% to approximately 15% by weight.

[0161] In some embodiments, the proportion of additional solvent added to the electrode slurry is less than 60% by weight, less than 58% by weight, less than 55% by weight, less than 52% by weight, less than 50% by weight, less than 48% by weight, less than 45% by weight, less than 42% by weight, less than 40% by weight, less than 38% by weight, less than 35% by weight, less than 32% by weight, less than 30% by weight, less than 28% by weight, less than 25% by weight, less than 22% by weight, less than 20% by weight, less than 18% by weight, less than 15% by weight, less than 12% by weight, less than 10% by weight, less than 8% by weight, or less than 5% by weight, based on the total weight of the slurry. In some embodiments, the proportion of additional solvent added to the electrode slurry is greater than 0% by weight, greater than 2% by weight, greater than 5% by weight, greater than 8% by weight, greater than 10% by weight, greater than 12% by weight, greater than 15% by weight, greater than 18% by weight, greater than 20% by weight, greater than 22% by weight, greater than 28% by weight, greater than 30% by weight, greater than 32% by weight, greater than 35% by weight, greater than 38% by weight, greater than 40% by weight, greater than 42% by weight, greater than 45% by weight, greater than 48% by weight, greater than 50% by weight, or greater than 52% by weight.

[0162] In some embodiments, the liquid content of the electrode slurry is based on the total weight of the slurry and ranges from approximately 1% to approximately 60% by weight, approximately 3% to approximately 60% by weight, approximately 5% to approximately 60% by weight, approximately 8% to approximately 60% by weight, approximately 10% to approximately 60% by weight, approximately 12% to approximately 60% by weight, approximately 15% to approximately 60% by weight, approximately 18% to approximately 60% by weight, approximately 20% to approximately 60% by weight, approximately 23% to approximately 60% by weight, approximately 25% to approximately 60% by weight, approximately 28% to approximately 60% by weight, and approximately 30% to approximately 60% by weight. Approximately 33% to 60% by weight, approximately 35% to 60% by weight, approximately 38% to 60% by weight, approximately 40% to 60% by weight, approximately 43% to 60% by weight, approximately 45% to 60% by weight, approximately 1% to 50% by weight, approximately 3% to 50% by weight, approximately 5% to 50% by weight, approximately 8% to 50% by weight, approximately 10% to 50% by weight, approximately 12% to 50% by weight, approximately 15% to 50% by weight, approximately 18% to 50% by weight, approximately 20% to 50% by weight, approximately 23% to 50% by weight Weight %, approximately 25% to approximately 50%, approximately 28% to approximately 50%, approximately 30% to approximately 50%, approximately 33% to approximately 50%, approximately 35% to approximately 50%, approximately 1% to approximately 40%, approximately 3% to approximately 40%, approximately 5% to approximately 40%, approximately 8% to approximately 40%, approximately 10% to approximately 40%, approximately 12% to approximately 40%, approximately 15% to approximately 40%, approximately 18% to approximately 40%, approximately 20% to approximately 40%, approximately 23% to approximately 40%, approximately 25% to approximately 40%, approximately The weights range from 1% to approximately 30%, 3% to approximately 30%, 5% to approximately 30%, 8% to approximately 30%, 10% to approximately 30%, 12% to approximately 30%, 15% to approximately 30%, 1% to approximately 20%, 3% to approximately 20%, 5% to approximately 20%, 8% to approximately 20%, 10% to approximately 20%, 1% to approximately 15%, 3% to approximately 15%, 5% to approximately 15%, or 1% to approximately 10%.

[0163] In some embodiments, the liquid content of the electrode slurry is less than 60% by weight, less than 58% by weight, less than 55% by weight, less than 53% by weight, less than 50% by weight, less than 48% by weight, less than 45% by weight, less than 43% by weight, less than 40% by weight, less than 38% by weight, less than 35% by weight, less than 33% by weight, less than 30% by weight, less than 28% by weight, less than 25% by weight, less than 23% by weight, less than 20% by weight, less than 18% by weight, less than 15% by weight, less than 12% by weight, less than 10% by weight, less than 8% by weight, or less than 5% by weight, based on the total weight of the slurry. In some embodiments, the liquid content of the electrode slurry is greater than 1% by weight, greater than 3% by weight, greater than 5% by weight, greater than 8% by weight, greater than 10% by weight, greater than 12% by weight, greater than 15% by weight, greater than 18% by weight, greater than 20% by weight, greater than 23% by weight, greater than 25% by weight, greater than 28% by weight, greater than 30% by weight, greater than 33% by weight, greater than 35% by weight, greater than 38% by weight, greater than 40% by weight, greater than 43% by weight, greater than 45% by weight, greater than 48% by weight, greater than 50% by weight, greater than 53% by weight, or greater than 55% by weight.

[0164] The homogenizer is equipped with a temperature control device, which can control the temperature of the dry electrode mixture or electrode slurry. Any homogenizer capable of reducing or removing particle aggregation and / or promoting a homogeneous distribution of electrode components in the dry electrode mixture or electrode slurry can be used herein. Homogeneous distribution plays a crucial role in producing a battery with good electrochemical performance. In some embodiments, the homogenizer is a tumbler, mill, agitator, or planetary mixer. In some embodiments, the homogenizer is grounded to reduce the effects of static electricity on the dry electrode mixture.

[0165] In some embodiments, the total homogenization time for producing a dry electrode mixture or electrode slurry is approximately 1 minute to 24 hours, approximately 5 minutes to 24 hours, approximately 10 minutes to 24 hours, approximately 15 minutes to 24 hours, approximately 30 minutes to 24 hours, approximately 60 minutes to 24 hours, approximately 2 hours to 24 hours, approximately 4 hours to 24 hours, approximately 6 hours to 24 hours, approximately 2 hours to 24 hours, approximately 8 hours to 24 hours, approximately 10 hours to 24 hours, approximately 12 hours to 24 hours, approximately 16 hours to 24 hours, approximately 1 minute to 16 hours, approximately 5 minutes to 16 hours, approximately 10 minutes to 16 hours, approximately 15 minutes to 16 hours, approximately 30 minutes to 16 hours, approximately 60 minutes to 16 hours, and approximately 2 hours to 1 6 hours, approximately 4 to 16 hours, approximately 6 to 16 hours, approximately 8 to 16 hours, approximately 10 to 16 hours, approximately 12 to 16 hours, approximately 1 minute to 12 hours, approximately 5 minutes to 12 hours, approximately 10 minutes to 12 hours, approximately 15 minutes to 12 hours, approximately 30 minutes to 12 hours, approximately 60 minutes to 12 hours, approximately 2 hours to 12 hours, approximately 4 hours to 12 hours, approximately 1 minute to 6 hours, approximately 5 minutes to 6 hours, approximately 10 minutes to 6 hours, approximately 15 minutes to 6 hours, approximately 30 minutes to 6 hours, approximately 60 minutes to 6 hours, approximately 2 hours to 6 hours, approximately 1 minute to 2 hours, approximately 5 minutes to 2 hours, approximately 10 minutes to 2 hours, approximately 15 minutes to 2 hours, or approximately 30 minutes to 2 hours.

[0166] In some embodiments, the total homogenization time for producing a dry electrode mixture or electrode slurry is less than 24 hours, less than 16 hours, less than 12 hours, less than 10 hours, less than 8 hours, less than 6 hours, less than 4 hours, less than 2 hours, less than 60 minutes, less than 30 minutes, or less than 15 minutes. In some embodiments, the total homogenization time for producing a dry electrode mixture or electrode slurry is more than 1 minute, more than 5 minutes, more than 10 minutes, more than 15 minutes, more than 30 minutes, more than 60 minutes, more than 2 hours, more than 4 hours, more than 6 hours, more than 8 hours, more than 10 hours, more than 12 hours, or more than 16 hours.

[0167] In some embodiments, the dry electrode mixture or electrode slurry is suitable for temperatures ranging from approximately 20°C to approximately 90°C, approximately 25°C to approximately 90°C, approximately 30°C to approximately 90°C, approximately 35°C to approximately 90°C, approximately 40°C to approximately 90°C, approximately 50°C to approximately 90°C, approximately 60°C to approximately 90°C, approximately 70°C to approximately 90°C, approximately 20°C to approximately 80°C, approximately 25°C to approximately 80°C, approximately 30°C to approximately 80°C, and approximately 35°C to approximately 80°C. The mixtures are mixed at temperatures of approximately 40°C to 80°C, 50°C to 80°C, 60°C to 80°C, 20°C to 70°C, 25°C to 70°C, 30°C to 70°C, 35°C to 70°C, 40°C to 70°C, 50°C to 70°C, 20°C to 60°C, 25°C to 60°C, 30°C to 60°C, 35°C to 60°C, or 40°C to 60°C.

[0168] In some embodiments, the dry electrode mixture or electrode slurry is mixed at a temperature below 90°C, below 80°C, below 70°C, below 60°C, below 50°C, or below 40°C. In some embodiments, the dry electrode mixture or electrode slurry is mixed at a temperature above 20°C, above 25°C, above 30°C, above 35°C, above 40°C, above 50°C, above 60°C, or above 70°C.

[0169] In a particular embodiment, the rotational speed of each rotating element in the homogenizer is independently about 100 rpm to about 3000 rpm, about 500 rpm to about 3000 rpm, about 1000 rpm to about 3000 rpm, about 1500 rpm to about 3000 rpm, about 100 rpm to about 2500 rpm, about 500 rpm to about 2500 rpm, about 1000 rpm to about 2500 rpm, about 1500 rpm to about 2500 rpm, about 100 rpm to about 2000 rpm, about 500 rpm to about 2000 rpm, about 1000 rpm to about 2000 rpm, about 100 rpm to about 1500 rpm, or about 500 rpm to about 1500 rpm.

[0170] In certain embodiments, the rotational speed of each rotating element in the homogenizer is independently less than 3000 rpm, less than 2500 rpm, less than 2000 rpm, less than 1500 rpm, or less than 1000 rpm. In certain embodiments, the rotational speed of each rotating element in the homogenizer is independently greater than 100 rpm, greater than 500 rpm, greater than 1000 rpm, greater than 1500 rpm, or greater than 2000 rpm.

[0171] After homogenization, the dried electrode mixture or electrode slurry can be used to manufacture electrodes. In some embodiments, the electrode comprises a current collector and an electrode layer formed on one or more surfaces of the current collector.

[0172] In some embodiments, the dry electrode mixture or electrode slurry can be homogenized and then applied to one or both sides of a current collector to form a coated electrode film. In some embodiments, the dry electrode mixture or electrode slurry is applied directly to the current collector or calendered. In some embodiments, the dry electrode mixture or electrode slurry is applied to a release film or calendered to form a self-supporting layer. This self-supporting layer is then combined with the current collector and pressurized to form a coated electrode film on the current collector.

[0173] In some embodiments, the dry electrode mixture can be coated using a molding press, roll press, extrusion press, or powder coater. In some embodiments, the molding press is a tablet press. In some embodiments, the extrusion press is a pellet mill or screw extruder. In certain embodiments, the electrode slurry can be coated using a doctor blade coater, slot die coater, transfer coater, roll coater, reverse coater, or gravure coater.

[0174] A current collector acts to collect electrons generated by the electrochemical reaction of the positive electrode active material, or to supply electrons necessary for the electrochemical reaction. In some embodiments, the current collector may be in the form of a foil, sheet, or film. In certain embodiments, the current collector is stainless steel, titanium, nickel, aluminum, copper, or an alloy thereof; or a conductive resin. In certain embodiments, the current collector has a two-layer structure consisting of an outer layer and an inner layer, the outer layer being made of a conductive material, and the inner layer being an insulating material or another conductive material; for example, aluminum attached with a conductive resin layer, or a polymer insulating material covered with an aluminum film. In some embodiments, the current collector has a three-layer structure consisting of an outer layer, an intermediate layer, and an inner layer, the outer and inner layers being made of a conductive material, and the intermediate layer being an insulating material or another conductive material, for example, a plastic substrate coated with a metal film on both sides. In certain embodiments, each of the outer layer, intermediate layer, and inner layer is independently stainless steel, titanium, nickel, aluminum, copper, or an alloy thereof, or a conductive resin. In some embodiments, the insulating material is a polymer-based material selected from the group consisting of polycarbonate, polyacrylate, polyacrylonitrile, polyester, polyamide, polystyrene, polyurethane, polyepoxy, poly(acrylonitrile-butadiene-styrene), polyimide, polyolefin, polyethylene, polypropylene, polyphenylene sulfide, poly(vinyl ester), polyvinyl chloride, polyether, oxidized polyphenyl, cellulose polymer, and combinations thereof. In certain embodiments, the current collector has a structure consisting of three or more layers.

[0175] In one embodiment, the conductive layer may be coated onto the current collector to improve its current conductivity. In certain embodiments, the conductive layer is composed of a material selected from the group consisting of carbon, carbon black, graphite, expanded graphite, graphene, graphene nanoplatelets, carbon fibers, carbon nanofibers, graphitized carbon flakes, carbon tubes, carbon nanotubes, activated carbon, mesoporous carbon, and combinations thereof. In some embodiments, the conductive layer is not composed of carbon, carbon black, graphite, expanded graphite, graphene, graphene nanoplatelets, carbon fibers, carbon nanofibers, graphitized carbon flakes, carbon tubes, carbon nanotubes, activated carbon, or mesoporous carbon.

[0176] In some embodiments, the conductive layer has a thickness of approximately 0.5 μm to approximately 5.0 μm. The thickness of the conductive layer affects the volume occupied by the current collector in the battery, as well as the amount of electrode active material required, and consequently, the capacity of the battery.

[0177] In certain embodiments, the thickness of the conductive layer on the current collector is approximately 0.5 μm to approximately 4.5 μm, approximately 1.0 μm to approximately 4.0 μm, approximately 1.0 μm to approximately 3.5 μm, approximately 1.0 μm to approximately 3.0 μm, approximately 1.0 μm to approximately 2.5 μm, approximately 1.0 μm to approximately 2.0 μm, approximately 1.1 μm to approximately 2.0 μm, approximately 1.2 μm to approximately 2.0 μm, approximately 1.5 μm to approximately 2.0 μm, approximately 1.8 μm to approximately 2.0 μm, approximately 1.0 μm to approximately 1.8 μm, approximately 1.2 μm to approximately 1.8 μm, approximately 1.5 μm to approximately 1.8 μm, approximately 1.0 μm to approximately 1.5 μm, or approximately 1.2 to approximately 1.5 μm. In some embodiments, the thickness of the conductive layer on the current collector is less than 4.5 μm, less than 4.0 μm, less than 3.5 μm, less than 3.0 μm, less than 2.5 μm, less than 2.0 μm, less than 1.8 μm, less than 1.5 μm, or less than 1.2 μm. In some embodiments, the thickness of the conductive layer on the current collector is greater than 1.0 μm, greater than 1.2 μm, greater than 1.5 μm, greater than 1.8 μm, greater than 2.0 μm, greater than 2.5 μm, greater than 3.0 μm, or greater than 3.5 μm.

[0178] The thickness of the current collector affects the volume it occupies within the battery and, consequently, the battery's energy density. In some embodiments, the current collector has a thickness of approximately 5 μm to approximately 30 μm. In specific embodiments, the current collector has a thickness of approximately 5 μm to approximately 20 μm, approximately 5 μm to approximately 15 μm, approximately 10 μm to approximately 30 μm, approximately 10 μm to approximately 25 μm, or approximately 10 μm to approximately 20 μm.

[0179] In some embodiments, a dry electrode mixture or electrode slurry is applied onto a current collector to form a coating film, and then the coating film is heated and / or dried. Any apparatus capable of heating and / or drying the coating film to adhere the coating film layer to the current collector can be used herein. Some non-limiting examples of apparatus that can be used to heat and / or dry the coating film include batch drying ovens, conveyor drying ovens, and microwave drying ovens. Some non-limiting examples of conveyor drying ovens include conveyor hot air drying ovens, conveyor resistance drying ovens, conveyor induction drying ovens, and conveyor microwave drying ovens. When the coating film is manufactured using a dry electrode mixture, drying may not be necessary because the initial liquid content is already negligible. However, heating may be necessary or advantageous to ensure fixation to the current collector. Even when the coating film is manufactured using a dry electrode mixture, it may be dried to further reduce the liquid content of the coating film.

[0180] The conditions for heating and / or drying the coating film are not particularly limited, but it is desirable that the coating film be securely fixed to the current collector without deformation or peeling after the heating and / or drying process. Therefore, it is desirable that the temperature be sufficiently high so that the heating and / or drying process can be completed within a reasonable time. At the same time, the temperature should be sufficiently low so that the electrode components in the coated electrode film do not degrade from heat, and to reduce the risk of significant temperature gradients due to uneven heating that could cause deformation or peeling of the electrodes.

[0181] In some embodiments, the coating film on the current collector is approximately 50°C to 160°C, approximately 60°C to 160°C, approximately 70°C to 160°C, approximately 80°C to 160°C, approximately 90°C to 160°C, approximately 95°C to 160°C, approximately 100°C to 160°C, approximately 105°C to 160°C, approximately 110°C to 160°C, approximately 115°C to 160°C, and approximately 120°C to 160°C. 160°C, approximately 125°C to approximately 160°C, approximately 130°C to approximately 160°C, approximately 140°C to approximately 160°C, approximately 60°C to approximately 150°C, approximately 70°C to approximately 150°C, approximately 80°C to approximately 150°C, approximately 90°C to approximately 150°C, approximately 95°C to approximately 150°C, approximately 100°C to approximately 150°C, approximately 105°C to approximately 150°C, approximately 110°C to approximately 150°C, approximately 115°C to approximately 150°C, approximately 120°C to approximately 150°C, approximately 60°C to approximately 140°C, approximately 70°C to approximately 140°C, approximately 80°C to approximately 140°C, approximately 90°C to approximately 140°C, approximately 95°C to approximately 140°C, approximately 100°C to approximately 140°C, approximately 105°C to approximately 140°C, approximately 110°C to approximately 140°C, approximately 115°C to approximately 140°C, approximately 120°C to approximately 140°C, approximately 60°C to approximately 130°C, approximately 70°C to approximately 130°C, approximately 80°C to approximately 130°C, approximately 90°C to approximately 130°C, approximately 97°C to approximately 130°C, approximately 100°C to approximately 130°C. It is heated and / or dried at temperatures ranging from approximately 105°C to 130°C, approximately 110°C to 130°C, approximately 60°C to 120°C, approximately 70°C to 120°C, approximately 80°C to 120°C, approximately 90°C to 120°C, approximately 95°C to 120°C, approximately 100°C to 120°C, approximately 60°C to 110°C, approximately 70°C to 110°C, approximately 80°C to 110°C, approximately 90°C to 110°C, approximately 60°C to 100°C, approximately 70°C to 100°C, or approximately 80°C to 100°C.

[0182] In some embodiments, the coating film on the current collector is heated and / or dried at a temperature below 160°C, below 150°C, below 140°C, below 130°C, below 120°C, below 115°C, below 110°C, below 105°C, below 100°C, below 95°C, below 90°C, below 80°C, or below 70°C. In some embodiments, the coating film on the current collector is heated and / or dried at a temperature above 60°C, above 70°C, above 80°C, above 90°C, above 95°C, above 100°C, above 105°C, above 110°C, above 115°C, above 120°C, above 130°C, or above 140°C.

[0183] After heating and / or drying, an electrode layer is formed. In some embodiments, to increase the density of the electrode layer, the electrode layer is mechanically compressed after heating and / or drying. In some embodiments, if the coated film contains a positive electrode active material, the electrode layer is specifically a positive electrode layer. In some embodiments, if the coated film consists of a negative electrode active material, the electrode layer is specifically a negative electrode layer.

[0184] As described above, the proportion of binder copolymer in the electrode layer can be the same as the proportion of binder copolymer in the solid portion of the dry electrode mixture or electrode slurry. Similarly, as described above, the proportions of conductive agent and electrode active material in the electrode layer can be the same as the proportions of conductive agent and electrode active material in the solid portion of the dry electrode mixture or electrode slurry.

[0185] In certain embodiments, the electrode layer thickness is approximately 5 μm to 90 μm, approximately 5 μm to 50 μm, approximately 5 μm to 25 μm, approximately 10 μm to 90 μm, approximately 10 μm to 50 μm, approximately 10 μm to 30 μm, approximately 15 μm to 90 μm, approximately 20 μm to 90 μm, approximately 25 μm to 90 μm, approximately 25 μm to 80 μm, approximately 25 μm to 70 μm, approximately 25 μm to 50 μm, approximately 30 μm to 90 μm, or approximately 30 μm to 80 μm. In some embodiments, the electrode layer thickness is greater than 5 μm, greater than 10 μm, greater than 15 μm, greater than 20 μm, greater than 25 μm, greater than 30 μm, greater than 40 μm, greater than 50 μm, greater than 60 μm, greater than 70 μm, or greater than 80 μm. In some embodiments, the electrode layer thickness is less than 90 μm, less than 80 μm, less than 70 μm, less than 60 μm, less than 50 μm, less than 40 μm, less than 30 μm, less than 25 μm, less than 20 μm, less than 15 μm, or less than 10 μm.

[0186] In some embodiments, the surface density of the electrode layer is approximately 1 mg / cm³. 2 From approximately 5 mg / cm³ 2 , about 3mg / cm 2 From approximately 50 mg / cm³ 2 , about 5mg / cm 2 From approximately 50 mg / cm³ 2 , about 10mg / cm 2 From approximately 50 mg / cm³ 2 , about 1mg / cm 2 From approximately 50 mg / cm³ 2 , about 20mg / cm 2 From approximately 50 mg / cm³ 2 , about 30mg / cm 2 From approximately 50 mg / cm³ 2 , about 1mg / cm 2 From approximately 30 mg / cm³ 2 , about 3mg / cm 2 From approximately 30 mg / cm³ 2 , about 5mg / cm 2 From approximately 30 mg / cm³ 2 , about 10mg / cm 2 From approximately 30 mg / cm³ 2, from about 15 mg / cm 2 to about 30 mg / cm 2 , from about 20 mg / cm 2 to about 30 mg / cm 2 , from about 1 mg / cm 2 to about 20 mg / cm 2 , from about 3 mg / cm 2 to 20 mg / cm 2 , from about 5 mg / cm 2 to about 20 mg / cm 2 , from about 10 mg / cm 2 to about 20 mg / cm 2 , from about 1 mg / cm 2 to about 15 mg / cm 2 , from about 3 mg / cm 2 to about 15 mg / cm 2 , from about 5 mg / cm 2 to about 15 mg / cm 2 , or from about 10 mg / cm 2 to about 15 mg / cm 2 is.

[0187] In some embodiments, the surface density of the electrode layer is less than 50 mg / cm 2 , less than 40 mg / cm 2 , less than 30 mg / cm 2 , less than 20 mg / cm 2 , less than 15 mg / cm 2 , less than 10 mg / cm 2 , less than 5 mg / cm 2 , or less than 3 mg / cm 2 is less than. In some embodiments, the surface density of the electrode layer is greater than 1 mg / cm 2 , greater than 3 mg / cm 2 , greater than 5 mg / cm 2 , greater than 10 mg / cm 2 , greater than 15 mg / cm 2 , greater than 20 mg / cm 2 , greater than 30 mg / cm 2 , or greater than 40 mg / cm 2 is greater than.

[0188] In some embodiments, the density of the electrode layer is about 0.5 g / cm3 Approximately 7.5 g / cm³ 3 , about 1g / cm 3 Approximately 7.5 g / cm³ 3 , about 1.5g / cm 3 Approximately 7.5 g / cm³ 3 , about 2g / cm 3 Approximately 7.5 g / cm³ 3 , about 2.5g / cm 3 Approximately 7.5 g / cm³ 3 , about 3.5g / cm 3 Approximately 7.5 g / cm³ 3 , about 4.5g / cm 3 Approximately 7.5 g / cm³ 3 , about 0.5g / cm 3 Approximately 5.5 g / cm³ 3 , about 1g / cm 3 Approximately 5.5 g / cm³ 3 , about 1.5g / cm 3 Approximately 5.5 g / cm³ 3 , about 2g / cm 3 Approximately 5.5 g / cm³ 3 , about 0.5g / cm 3 Approximately 5.5 g / cm³ 3 , about 1g / cm 3 Approximately 5.5 g / cm³ 3 , about 1.5g / cm 3 Approximately 5.5 g / cm³ 3 , about 2g / cm 3 Approximately 5.5 g / cm³ 3 , about 2.5g / cm 3 Approximately 5.5 g / cm³ 3 , about 0.5g / cm 3 Approximately 2.5 g / cm³ 3 , about 1g / cm 3 Approximately 2.5 g / cm³ 3 , or approximately 1.5 g / cm³ 3 Approximately 2.5 g / cm³ 3 In some embodiments, the density of the electrode layer is 7.5 g / cm³. 3 Less than 6.5 g / cm³ 3 Less than 5.5 g / cm³ 3 Less than 4.5 g / cm³ 3 Less than 3.5 g / cm³ 3 Less than 2.5 g / cm³ 3 Less than 2 g / cm³3 Less than 1.5 g / cm³ 3 It is less than 0.5 g / cm³. In some embodiments, the density of the electrode layer is 0.5 g / cm³. 3 Larger than 1 g / cm³ 3 Larger, 1.5 g / cm 3 Larger than 2g / cm³ 3 Larger, 2.5 g / cm 3 Larger, 3.5 g / cm 3 Larger, 4.5 g / cm 3 Larger than 5.5 g / cm³ 3 Larger.

[0189] Furthermore, electrodes prepared using a dry electrode mixture or electrode slurry manufactured with the binder composition of the present invention exhibit strong adhesion of the electrode layer to the current collector. Having good peel strength of the electrode layer relative to the current collector is important to prevent electrode peeling and separation, which significantly affect the mechanical stability of the electrode and the cycle life of the battery. Therefore, it is desirable that the electrode has sufficient peel strength to withstand the rigors of battery manufacturing.

[0190] In some embodiments, the peel strength between the current collector and the electrode layer is approximately 1.0 N / cm to approximately 8.0 N / cm, approximately 1.0 N / cm to approximately 6.0 N / cm, approximately 1.0 N / cm to approximately 5.0 N / cm, approximately 1.0 N / cm to approximately 4.0 N / cm, approximately 1.0 N / cm to approximately 3.0 N / cm, approximately 1.0 N / cm to approximately 2.5 N / cm, approximately 1.0 N / cm to approximately 2.0 N / cm, approximately 1.2 N / cm to approximately 3.0 N / cm, approximately 1.2 N / cm to approximately 2.5 N / cm, approximately 1.2 N / cm to approximately 2.0 N / cm, approximately 1.2 N / cm to approximately 2.0 N / cm, approximately 1.5 N / cm to approximately 3.0 N / cm, approximately 1.5 N / cm to approximately 2.5 N / cm, approximately 1.5 N / cm to approximately 2.0 N / cm, approximately 1.8 N / cm to approximately 3.0 N / cm, and approximately 1.8 The ranges are approximately 2.5 N / cm to 2.5 N / cm, 6.0 N / cm to 2.0 N / cm, 5.0 N / cm to 2.0 N / cm, 3.0 N / cm to 2.0 N / cm, 3.0 N / cm to 2.5 N / cm, 3.0 N / cm to 2.2 N / cm, 3.0 N / cm to 2.5 N / cm, 8.0 N / cm to 3.0 N / cm, 6.0 N / cm to 3.0 N / cm, or 6.0 N / cm to 4.0 N / cm.

[0191] In some embodiments, the peel strength between the current collector and the electrode layer can be greater than 1.0 N / cm, greater than 1.2 N / cm, greater than 1.5 N / cm, greater than 2.0 N / cm, greater than 2.2 N / cm, greater than 3.0 N / cm, greater than 3.5 N / cm, greater than 4.0 N / cm, greater than 4.5 N / cm, greater than 5.0 N / cm, greater than 5.5 N / cm, greater than 6.0 N / cm, greater than 6.5 N / cm, or greater than 7.0 N / cm. In some embodiments, the peel strength between the current collector and the electrode layer is less than 8.0 N / cm, less than 7.5 N / cm, less than 7 N / cm, less than 6.5 N / cm, less than 6.0 N / cm, less than 5.5 N / cm, less than 5.0 N / cm, less than 4.5 N / cm, less than 4.0 N / cm, less than 3.5 N / cm, less than 3.0 N / cm, less than 2.8 N / cm, less than 2.5 N / cm, less than 2.2 N / cm, less than 2.0 N / cm, less than 1.8 N / cm, or less than 1.5 N / cm.

[0192] Figure 1 is a flowchart illustrating a simplified summary of several embodiments of various aspects of the present invention disclosed herein. As shown, following polymerization, the post-reaction mixture is dried until it is substantially water-free. If the desired binder composition is a dry binder composition, the dried post-reaction mixture is the binder composition. If the desired binder composition is a semi-dry binder composition, the dried post-reaction mixture is instead rehydrated to form a binder composition. To form a dry electrode mixture from a dry binder composition, the dry binder composition is mixed with an electrode active material and optionally a conductive agent. To form a semi-dry electrode slurry from a dry binder composition, the dry binder composition is mixed with an electrode active material and additional solvents, as well as optionally a conductive agent. To form a semi-dry electrode slurry from a semi-dry binder composition, the semi-dry binder composition is mixed with an electrode active material, as well as optionally a conductive agent and / or additional solvents.

[0193] The binder compositions disclosed herein offer several advantages. Most importantly, the lower liquid content of the binder compositions disclosed herein, compared to conventional wet binder compositions, ensures higher efficiency in the storage and transport of the binder compositions, thereby helping to streamline the supply chain for electrode manufacturing. The dry binder compositions disclosed herein have been found to be usable directly in dry electrode mixtures as well as in electrode slurries after being rehydrated into semi-dry binder compositions. In either case, batteries containing electrodes manufactured using the dry or semi-dry binder compositions disclosed herein have been found to have similar mechanical and electrochemical performance to batteries containing electrodes manufactured using conventional wet binder compositions. Overall, this demonstrates that the binder compositions disclosed herein have superior binder performance and that the binder copolymers within the disclosed binder compositions are effective in both dry and rehydrated states, thereby demonstrating the versatility of the copolymers.

[0194] The following embodiments are provided to illustrate embodiments of the present invention, but are not intended to limit the invention to any specific embodiment. Unless otherwise indicated, all parts and percentages are by weight. All numerical values ​​are approximate. Where numerical ranges are given, it should be understood that embodiments outside those ranges may still fall within the scope of the invention. Specific details disclosed in each embodiment should not be construed as essential features of the invention.

[0195] Examples The peel strength of the electrode layer was measured using a tensile testing machine (DZ-106A, obtained from Dongguan Zonhow Test Equipment Co. Ltd., China). This test measures the average force required to peel the electrode layer from the current collector at a 180° angle, measured in Newtons. The average roughness depth (Rz) of the current collector was 2 μm. A strip of adhesive tape (3M, USA, model number 810) with a width of 18 mm and a length of 20 mm was attached to the surface of the electrode layer. The electrode piece was placed in the testing machine, the tape was folded back 180 degrees, and then placed in the movable jaws. It was pulled at room temperature and a peeling speed of 200 mm / min. The maximum peeling force measured was defined as the peel strength. The measurement was repeated three times, and the average value was calculated.

[0196] The solid content of the binder composition, dry electrode mixture, or electrode slurry was calculated from the change in mass of the binder composition, dry electrode mixture, or electrode slurry before and after drying. Approximately 1 g of the binder composition, dry electrode mixture, or electrode slurry was weighed into a weighing bottle and dried in a vacuum dryer at 110 ± 5°C and -0.09 MPa for at least 5 hours. The dried binder composition, dry electrode mixture, or electrode slurry was cooled in a desiccator for approximately 15 minutes, and its mass was measured. The difference in mass of the binder composition, dry electrode mixture, or electrode slurry before and after drying was determined, and the solid content concentration of the binder composition, dry electrode mixture, or electrode slurry was calculated using the following formula. "Solid content of x" = "Mass of x after drying" / "Mass of x before drying" × 100% Here, x may refer to a binder composition, a dry electrode mixture, or an electrode slurry.

[0197] The weight-average molecular weight and number-average molecular weight of the water-compatible copolymer were measured by gel permeation chromatography. The binder composition consisting of this copolymer was first dissolved in dimethylformamide at room temperature. Once the binder composition was dissolved, the solution was carefully filtered through a 0.45 μm filter to prepare the sample. A calibration curve was created using polystyrene standards to calculate the weight-average molecular weight and number-average molecular weight of the copolymer. The obtained sample was analyzed using an Agilent PLgel 5um MIXED-C column. The flow rate was 1 mL / min, and the sample weight was 2 mg. A Waters 2414 Refractive Index (RI) detector was used, and the detection temperature was 35°C.

[0198] Example 1 A) Preparation of binder composition 17.96 g of sodium hydroxide (NaOH) was added to a round-bottom flask containing 380 g of distilled water. This mixture was stirred at 80 rpm for 30 minutes to obtain the first suspension.

[0199] 35.67 g of acrylic acid was added to the first suspension. This mixture was further stirred at 80 rpm for 30 minutes to obtain a second suspension.

[0200] 18.84 g of acrylamide was dissolved in 10 g of DI water to prepare an acrylamide solution. Then, the entirety of the acrylamide solution was added to the second suspension. This mixture was further heated to 55°C and stirred at 80 rpm for 45 minutes to obtain a third suspension.

[0201] 12.73 g of acrylonitrile was added to the third suspension. This mixture was further stirred at 80 rpm for 10 minutes to obtain the fourth suspension.

[0202] Furthermore, 0.015 g of a water-soluble free radical initiator (ammonium persulfate, APS; obtained from Aladdin Industrial Co., Ltd., China) was dissolved in 3 g of DI water, and 0.0075 g of a reducing agent (sodium bisulfite; obtained from Tianjin Cannabis Chemical Reagent Factory, China) was dissolved in 1.5 g of DI water. All of the APS solution and sodium bisulfite solution were added to the fourth suspension. This mixture was stirred at 200 rpm at 55°C for 24 hours to obtain the fifth suspension.

[0203] After the reaction was complete, the temperature of the fifth suspension was lowered to 25°C. 3.72 g of NaOH was dissolved in 400 g of DI water, and the entire sodium hydroxide solution was added dropwise to the fifth suspension to adjust the pH to 7.3, forming the sixth suspension. The sixth suspension was filtered using a 200 μm nylon mesh. The solid content of the filtered sixth suspension was 9.00 wt%.

[0204] The filtered sixth suspension was dried overnight at 60°C in a vacuum dryer, and then ground using a mortar and pestle to form a dry binder composition in the form of a fine powder. The weight-average molecular weight of this binder composition was 140,300 g / mol, the number-average molecular weight was 61,500 g / mol, and the polydispersity index was 2.28.

[0205] B) Fabrication of the positive electrode First, 0.9 g of conductive agent (KS6: ANR Technologies Pte. Ltd., obtained from Singapore), 0.90 g of binder composition, and 28.2 g of NMC532 (Shandong Tianjiao New Energy Co. Ltd.; obtained from China) were ground in a mill to obtain a homogeneous mixture. Then, 20.0 g of DI water was added and further ground to form a homogenized positive electrode slurry. The solid content concentration of this positive electrode slurry was 60 wt%.

[0206] This positive electrode slurry was applied to one side of a 16 μm thick aluminum foil to be used as a current collector. The coating on the aluminum foil was dried in a hot air dryer (DHG10H, Huyue Equipment Co., Ltd., China) at approximately 80°C for 120 minutes to form the positive electrode layer. After that, the electrode was pressed to make the positive electrode layer 34 μm thick and the surface density 5 mg / cm². 2 It was reduced to that level.

[0207] C) Assembly of coin-type batteries A CR2032 coin-type lithium battery was assembled in an argon-filled glove box. The positive electrode sheet was cut into a disc-shaped positive electrode. A 500 μm thick lithium metal foil was used for the negative electrode. The positive and negative electrodes were separated by a separator. The separator was a ceramic-coated nonwoven microporous membrane (MPM, Japan) with a thickness of approximately 25 μm. The electrode assembly was dried under vacuum in a box-type resistance oven (DZF-6020, Shenzhen Kejing Star Technology Co. Ltd., obtained from China) at 105°C for approximately 16 hours. The moisture content of the separator and electrode assembly after drying was 200 ppm and 300 ppm, respectively.

[0208] Next, under a high-purity argon atmosphere with water and oxygen content of less than 3 ppm each, the electrolyte was injected into the case holding the filled electrodes. The electrolyte was a solution of LiPF6 (1M) mixed with ethylene carbonate (EC), ethyl methyl carbonate (EMC), and dimethyl carbonate (DMC) in a 1:1:1 volume ratio. After filling with the electrolyte, the coin cell was mechanically pressed using a standard circular punch die.

[0209] D) Electrochemical measurements Coin cells were analyzed in constant current mode using a multi-channel battery tester (BTS-4008-5V10mA, Neware Electronics Co. Ltd, obtained from China). The first cycle was completed with a C / 20 voltage between 3.0V and 4.3V at 25°C, and the discharge capacity corresponding to that cycle was measured. The electrochemical performance of the coin cell of Example 1 was measured and is shown in Table 1 below.

[0210] Example 2 The cathode was prepared in the same manner as in Example 1, except that 7.45 g of sodium hydroxide was added in the preparation of the first suspension, 16.77 g of acrylic acid was added in the preparation of the second suspension, 7.19 g of acrylamide was added in the preparation of the third suspension, and 35.55 g of acrylonitrile was added in the preparation of the fourth suspension. The solid content concentration of the filtered sixth suspension was 8.88% by weight. The weight-average molecular weight of the binder composition was 160,900 g / mol, the number-average molecular weight was 71,000 g / mol, and the polydispersity index was 2.27.

[0211] Example 3 The positive electrode was prepared in the same manner as in Example 1, except that 30.10 g of sodium hydroxide was added in the preparation of the first suspension, 56.92 g of acrylic acid was added in the preparation of the second suspension, 7.19 g of acrylamide was added in the preparation of the third suspension, and 5.90 g of acrylonitrile was added in the preparation of the fourth suspension. The solid content of the filtered sixth suspension was 9.82% by weight.

[0212] Example 4 The cathode was prepared in the same manner as in Example 1, except that 5.02 g of sodium hydroxide was added in the preparation of the first suspension, 12.39 g of acrylic acid was added in the preparation of the second suspension, 23.73 g of acrylamide was added in the preparation of the third suspension, and 26.84 g of acrylonitrile was added in the preparation of the fourth suspension. The solid content of the filtered sixth suspension was 8.64% by weight.

[0213] Example 5 The positive electrode was prepared in the same manner as in Example 1, except that 11.90 g of sodium hydroxide was added in the preparation of the first suspension, 24.50 g of acrylic acid was added in the preparation of the second suspension, 7.19 g of acrylamide was added in the preparation of the third suspension, and 29.71 g of acrylonitrile was added in the preparation of the fourth suspension. The solid content of the filtered sixth suspension was 8.38% by weight.

[0214] Example 6 The cathode was prepared in the same manner as in Example 1, except that 3.00 g of sodium hydroxide was added in the preparation of the first suspension, 8.75 g of acrylic acid was added in the preparation of the second suspension, 7.19 g of acrylamide was added in the preparation of the third suspension, and 41.86 g of acrylonitrile was added in the preparation of the fourth suspension. The solid content of the filtered sixth suspension was 7.22% by weight.

[0215] Example 7 A) Preparation of binder composition A binder composition was prepared in the same manner as in Example 1, except that after drying and grinding the filtered sixth suspension, the resulting dry powder was mixed with DI water to prepare a binder composition with a mass ratio of DI water to dry powder of 1:2. This binder composition was a semi-dried binder composition with a liquid content of 33.3 wt%.

[0216] B) Fabrication of the positive electrode In preparing a homogeneous cathode slurry, the cathode was prepared in the same manner as in Example 1, except that 1.35 g of the above binder composition (liquid content 33.3 wt%) and 19.55 g of DI water were added.

[0217] Example 8 A) Preparation of binder composition A binder composition was prepared in the same manner as in Example 1, except that after drying and grinding the filtered sixth suspension, the resulting dry powder was mixed with DI water to prepare a binder composition in a mass ratio of DI water to dry powder of 1:1. This binder composition was a semi-dry binder composition with a liquid content of 50 wt%.

[0218] B) Fabrication of the positive electrode The cathode was prepared in the same manner as in Example 1, except that 1.80 g of the above binder composition (liquid content 50 wt%) and 19.10 g of DI water were added in the preparation of the homogeneous cathode slurry.

[0219] Example 9 A) Preparation of binder composition A binder composition was prepared in the same manner as in Example 1, except that after drying and grinding the filtered sixth suspension, the resulting dry powder was mixed with DI water to prepare a binder composition with a mass ratio of DI water to dry powder of 2:1. This binder composition was a semi-dried binder composition with a liquid content of 66.7 wt.%.

[0220] B) Fabrication of the positive electrode In preparing a homogeneous cathode slurry, the cathode was prepared in the same manner as in Example 1, except that 2.70 g of the above binder composition (liquid content 66.7 wt%) and 18.20 g of DI water were added.

[0221] Example 10 A) Preparation of binder composition A binder composition was prepared in the same manner as in Example 1, except that the filtered sixth suspension was dried and pulverized, and the resulting dry powder was mixed with DI water to prepare a binder composition with a mass ratio of DI water to dry powder of 4:1. This binder composition was a semi-dry binder composition with a liquid content of 80 wt%.

[0222] Fabrication of the positive electrode In preparing a homogeneous cathode slurry, the cathode was prepared in the same manner as in Example 1, except that 4.50 g of the above binder composition (liquid content 80 wt%) and 17.30 g of DI water were added.

[0223] Example 11 A) Preparation of binder composition A binder composition was prepared in the same manner as in Example 1.

[0224] B) Fabrication of the positive electrode 0.24 g of a conductive agent (KS6; obtained from ANR Technologies Pte. Ltd., Singapore), 0.36 g of a binder composition, and 0.60 g of NMC532 (obtained from Shandong Tianjiao New Energy Co. Ltd., China) were pulverized using a mill to form a dried and homogenized positive electrode mixture.

[0225] 0.2 g of this homogenized positive electrode mixture was pressure-bonded onto one side of a 16-μm-thick aluminum foil as a current collector by hot pressing. The coating film on this aluminum foil was vacuum-dried at about 80 °C for 6 hours to form a positive electrode layer.

[0226] Example 12 A positive electrode was fabricated in the same manner as in Example 11, except that the binder composition used was prepared in the same manner as in Example 2.

[0227] Example 13 A positive electrode was fabricated in the same manner as in Example 1, except that NMC532 was replaced with the same weight of LCO.

[0228] Example 14 A positive electrode was fabricated in the same manner as in Example 1, except that NMC532 was replaced with the same weight of LFP (manufactured in China by Tianjin Sitelan Energy Technology Co., Ltd.).

[0229] Assembly of Coin Cells of Examples 2 - 14 The coin cells of Examples 2 - 14 were assembled in the same manner as in Example 1.

[0230] Electrochemical Measurements of Examples 2 - 13 Analysis of the coin cells of Examples 2 - 13 was performed in the same manner as in Example 1. The electrochemical performance of the coin cells of Examples 2 - 13 was measured and shown in Table 1 below.

[0231] Electrochemical Measurements of Example 14 The electrochemical performance of the coin cell in Example 14 was measured in the same manner as in Example 1, except that cycling was performed between 2.0V and 3.65V, and is shown in Table 1 below.

[0232] Comparative Example 1 A positive electrode was prepared in the same manner as in Example 1, except that 0.9 g of dried sodium polyacrylate (Sigma-Aldrich, Germany) was used as the binder composition.

[0233] Comparative Example 2 The cathode was prepared in the same manner as in Example 1, except that 0.9 g of dried polyacrylamide (Sigma-Aldrich, Germany) was used as the binder composition.

[0234] Comparative Example 3 The cathode was prepared in the same manner as in Example 1, except that 0.9 g of dried polyacrylonitrile (Sigma-Aldrich, Germany) was used as the binder composition.

[0235] Comparative Example 4 The positive electrode was prepared in the same manner as in Example 1, except that 24.14 g of sodium hydroxide was added in the preparation of the first suspension, 46.84 g of acrylic acid was added in the preparation of the second suspension, acrylamide was not added in the preparation of the third suspension, and 18.57 g of acrylonitrile was added in the preparation of the fourth suspension. The solid content of the filtered sixth suspension was 9.63% by weight.

[0236] Comparative Example 5 The cathode was prepared in the same manner as in Example 1, except that 26.13 g of sodium hydroxide was added in the preparation of the first suspension, 50.44 g of acrylic acid was added in the preparation of the second suspension, 21.32 g of acrylamide was added in the preparation of the third suspension, and acrylonitrile was not added in the preparation of the fourth suspension. The solid content of the filtered sixth suspension was 9.92% by weight.

[0237] Comparative Example 6 The positive electrode was prepared in the same manner as in Example 1, except that 1.86 g of sodium hydroxide was added in the preparation of the first suspension, acrylic acid was not added in the preparation of the second suspension, 21.32 g of acrylamide was added in the preparation of the third suspension, 37.14 g of acrylonitrile was added in the preparation of the fourth suspension, and sodium hydroxide was not added in the preparation of the sixth suspension. The solid content of the filtered sixth suspension was 7.15% by weight.

[0238] Comparative Example 7 A) Preparation of binder composition A binder composition was prepared in the same manner as in Comparative Example 4, except that the filtered sixth suspension was dried and pulverized, and the resulting dry powder was mixed with DI water to prepare a binder composition with a mass ratio of DI water to dry powder of 2:1. This binder composition was a semi-dried binder composition with a liquid content of 66.7 wt%.

[0239] B) Fabrication of the positive electrode In preparing a homogeneous cathode slurry, the cathode was prepared in the same manner as in Example 1, except that 2.70 g of the above binder composition (liquid content 66.7 wt%) and 18.20 g of DI water were added.

[0240] Comparative Example 8 The positive electrode was prepared in the same manner as in Example 11, except that 0.9 g of dried sodium polyacrylate (Sigma-Aldrich, Germany) was used as the binder composition.

[0241] Comparative Example 9 The cathode was prepared in the same manner as in Example 11, except that 0.9 g of dried polyacrylamide (Sigma-Aldrich, Germany) was used as the binder composition.

[0242] Comparative Example 10 The positive electrode was prepared in the same manner as in Example 11, except that 0.9 g of dried polyacrylonitrile (Sigma-Aldrich, Germany) was used as the binder composition.

[0243] Comparative Example 11 A positive electrode was fabricated in the same manner as in Example 11, except that the binder composition was prepared in the same manner as in Comparative Example 4.

[0244] Comparative Example 12 A positive electrode was fabricated in the same manner as in Example 11, except that the binder composition was prepared in the same manner as in Comparative Example 5.

[0245] Comparative Example 13 A positive electrode was fabricated in the same manner as in Example 11, except that the binder composition was prepared in the same manner as in Comparative Example 6.

[0246] Assembly of Coin Cells of Comparative Examples 1-13 Coin cells of Comparative Examples 1-13 were assembled in the same manner as in Example 1.

[0247] Electrochemical Measurements of Comparative Examples 1-13 Coin cells of Comparative Examples 1-13 were analyzed in the same manner as in Example 1. The electrochemical performance of the coin cells of Comparative Examples 1-13 was measured and shown in Table 2 below.

[0248]

Table 1

[0249]

Table 2

[0250] Although the present invention has been described with respect to a limited number of embodiments, the particular features of one embodiment should not be attributed to other embodiments of the present invention. In some embodiments, the method can include a number of steps not mentioned herein. In other embodiments, the method does not include or substantially does not include any step not listed herein. There are variations and modifications from the described embodiments. The appended claims are intended to cover all such modifications and variations as being within the scope of the present invention.

Claims

1. A binder composition comprising a water-compatible copolymer, wherein the binder composition has a liquid content of less than 85% by weight based on the total weight of the binder composition.

2. The binder composition according to claim 1, wherein the binder composition has a liquid content of less than 50% by weight or less than 25% by weight based on the total weight of the binder composition.

3. The binder composition according to claim 1, wherein the binder composition has a liquid content of less than 1% by weight based on the total weight of the binder composition.

4. The binder composition according to claim 1, wherein the water-compatible copolymer comprises structural unit (a) derived from an acid group-containing monomer, the acid group being selected from carboxylic acids, sulfonic acids, sulfuric acids, phosphonic acids, phosphoric acids, nitric acids, salts of these acids, derivatives of these acids, and combinations thereof, and the proportion of structural unit (a) in the copolymer is from about 5 mol% to about 95 mol%, based on the total number of moles of monomer units in the copolymer.

5. The binder composition according to claim 1, wherein the water-compatible copolymer further comprises structural units (b) derived from monomers selected from the group consisting of amide group-containing monomers, hydroxyl group-containing monomers, and combinations thereof, and the proportion of structural units (b) in the copolymer is about 5 mol% to about 90 mol% based on the total number of moles of monomer units in the copolymer.

6. The binder composition according to claim 1 or 5, wherein the water-compatible copolymer further comprises structural units (c) derived from monomers selected from the group consisting of nitrile group-containing monomers, ester group-containing monomers, ether group-containing monomers, epoxy group-containing monomers, carbonyl group-containing monomers, fluorine-containing monomers, and combinations thereof, and the proportion of structural units (c) in the copolymer is about 10 mol% to about 95 mol% based on the total number of moles of monomer units in the copolymer.

7. The binder composition according to claim 1, wherein the liquid content is derived from an aqueous solvent.

8. The binder composition according to claim 7, wherein the aqueous solvent is water.

9. The binder composition according to claim 1, wherein the weight-average molecular weight of the water-compatible copolymer in the binder composition is about 10,000 g / mol to about 1,000,000 g / mol.

10. The binder composition according to claim 1, wherein the number average molecular weight of the water-compatible copolymer in the binder composition is approximately 10,000 g / mol to approximately 500,000 g / mol.

11. The binder composition according to claim 1, wherein the polydispersity index of the water-compatible copolymer in the binder composition is about 1 to about 20.

12. An electrode slurry comprising the binder composition and electrode active material according to claim 1, wherein the electrode slurry has a liquid content of about 1% to about 60% by weight based on the total weight of the electrode slurry.

13. The electrode slurry according to claim 12, further comprising a conductive agent.

14. The electrode slurry according to claim 12, wherein the liquid content of the electrode slurry is derived from an aqueous solvent.

15. The electrode slurry according to claim 14, wherein the aqueous solvent is water.

16. The electrode slurry according to claim 12, wherein the proportion of electrode active material in the solid portion of the electrode slurry is about 40% by weight to about 99% by weight based on the total weight of the solid portion of the electrode slurry.

17. A dry electrode mixture comprising the binder composition and electrode active material according to claim 3.

18. The dry electrode mixture according to claim 17, wherein the dry electrode mixture further comprises a conductive agent.

19. The dry electrode mixture according to claim 17, wherein the proportion of electrode active material in the dry electrode mixture is about 40% by weight to about 99% by weight based on the total weight of the dry electrode mixture.

20. The dry electrode mixture according to claim 17, wherein the dry electrode mixture has a liquid content of less than 1% by weight based on the total weight of the dry electrode mixture.

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