Secondary battery components

Abstract

Disclosed is a binder composition that can be used in dry electrode mixes or electrode slurries for producing electrodes. The binder composition includes a water-compatible copolymer and has a liquid content of less than 85 wt. % based on the total weight of the binder composition. The reduced liquid content of the binder composition improves transportation and storage efficiency compared to conventional wet binder compositions. The binder compositions disclosed herein are versatile and can be successfully used in dry electrode mixes and electrode slurries. Batteries containing electrodes prepared using the binder compositions disclosed herein have electrochemical performance comparable to batteries containing electrodes produced via conventional wet binder compositions.

Description

[Technical Field]

[0001] The present invention relates to the field of batteries. In particular, the present invention relates to binder compositions that can be used in electrode slurries and dry electrode mixes for lithium-ion and other metal-ion batteries.

[0002] Over the past few decades, lithium-ion batteries (LIBs) have become widely used in various applications, especially in home appliances, due to their excellent energy density, long cycle life, and high discharge capacity. With the rapid market development of electric vehicles (EVs) and grid energy storage, LIBs, with their high performance and low cost, are currently one of the most promising options for large-scale energy storage devices.

[0003] Lithium-ion battery electrodes generally consist of an electrode active material, conductive carbon, and a binder composition. The binder composition provides good electrochemical stability for the electrode layer, binds the electrode layer materials together, and adheres them to the current collector. Electrodes are often formed using a slurry, in which the various electrode components are suspended or dissolved in a solvent for ease of processing and coating. Polyvinylidene fluoride (PVDF) is one of the most commonly used binder polymers in the commercial lithium-ion battery industry. While it functions as a binder composition by itself, PVDF is only soluble in certain organic solvents, such as N-methyl-2-pyrrolidone (NMP). Therefore, these organic solvents are used as the solvent for PVDF electrode slurries. However, NMP is flammable and toxic, so care must be taken when handling it. Furthermore, the drying process requires the installation of an NMP recovery system to recover NMP vapor. This requires a large capital investment and adds significant costs to the manufacturing process.

[0004] Considering the drawbacks of using organic solvent-based slurries to form electrodes, the use of aqueous solvents, most commonly water, as slurries has been considered. Because PVDF is insoluble and poorly dispersible in water, aqueous electrode slurries use binder polymers that are compatible with water instead of PVDF. Conventional methods for producing such polymers require large amounts of aqueous solvent during the polymerization process, so binder compositions consisting of a polymer and a large amount of aqueous solvent are the easiest to produce.

[0005] When scaled up to an industrial scale, the large amount of aqueous solvent present in the binder composition poses storage problems because even a moderate amount of binder composition requires a large amount of space. Furthermore, in industrial situations, binder composition production and electrode production are not always performed at the same location, so the finished binder composition may need to be transported to a separate facility for electrode production. 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 would pose significant logistical challenges to the efficient production of electrodes.

[0006] U.S. Patent No. 10,741,843 discloses a process for manufacturing an electrode layer in which an electrode active material, conductive carbon, and dry PVDF as a binder composition are mixed and then directly calendered onto a current collector without the addition of a solvent. In other words, a dry electrode mixture is used to manufacture the electrode layer, but the use of PVDF, a water-insoluble polymer, is essential. Because PVDF is immiscible with water, it is readily available in a dry state, making it easy to prepare the dry electrode mixture. This makes PVDF particularly suitable for the manufacture of dry electrode mixtures, which explains why dry PVDF was selected to manufacture the dry electrode layer in the patent document.

[0007] On the other hand, water-compatible polymers are not as readily available in a dry state. Some water-compatible polymers irreversibly change form after drying, making it more difficult to separate and dry them to form a binder composition that is substantially liquid-free. That is, even if water is replenished, such polymers may not return to their pre-drying form, resulting in permanent deterioration of the binder performance when they dry. Furthermore, some binder compositions made of water-soluble polymers have a high affinity for aqueous solvents and cannot be easily separated, making it difficult to even reduce the liquid content of the binder composition without completely drying it. Summary of the Invention

[0008] Therefore, the present inventors have conducted extensive research and found that a water-compatible binder composition with reduced liquid content (to the extent that substantially no liquid remains) can be easily produced by processing a wet binder composition containing the water-soluble copolymer disclosed herein and an aqueous solvent. Batteries containing electrodes manufactured using the binder composition disclosed herein have electrochemical performance equivalent to that of batteries containing electrodes manufactured using conventional wet binder compositions. Therefore, an object of the present invention is to provide a binder composition with reduced liquid content that contains a water-compatible copolymer and can maintain binder performance equivalent to that of conventional wet binder compositions. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a flowchart outlining various aspects disclosed herein. DETAILED DESCRIPTION OF THE INVENTION

[0010] The aforementioned needs are met by various aspects and embodiments disclosed herein. In one aspect, provided herein is a binder composition that can be used in a dry electrode mix or electrode slurry to fabricate an electrode, the binder composition comprising a water-compatible copolymer, and the binder composition having a liquid content of less than 85 wt %, based on the total weight of the binder composition. In another aspect, various dry electrode mixes and electrode slurries utilizing such binder compositions are disclosed. Despite having a reduced liquid content, the binder compositions disclosed herein can retain binder performance comparable to that of conventional wet binder compositions. Furthermore, batteries including electrodes fabricated using the binder compositions disclosed herein have electrochemical performance comparable to batteries including electrodes fabricated via wet binder compositions.

[0011] In one aspect, provided herein is a binder composition that can be used in a dry electrode mix or electrode slurry to manufacture an electrode, the binder composition comprising a water-compatible copolymer, and the binder composition having a reduced liquid content compared to conventional wet binder compositions. In another aspect, various dry electrode mixes and electrode slurries utilizing such binder compositions are disclosed. In yet another aspect, electrodes prepared using the dry electrode mixes and slurries are disclosed.

[0012] The term "electrode" refers to a "cathode" or an "anode." In some embodiments, an electrode is composed 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 an electrode layer and can conduct current to the electrode during discharge or charging 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 thereon, such as a carbon black-based coating layer. The conductive metal layer or substrate may be in the form of a foil or a porous body having a three-dimensional network structure, and may be a polymeric 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 of electrochemically active material in contact with the current collector. In some embodiments, the electrode layer is made by applying a coating onto 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 the electrode layer.

[0016] The term "polymer" refers to a macromolecular compound prepared by polymerizing monomers, whether of the same or different types. The generic term "polymer" encompasses the terms "homopolymer" as well as "copolymer."

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

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

[0019] The term "water compatibility" in reference to a chemical compound, a mixture of compounds, or a polymer refers to the ability of the chemical compound, a mixture of compounds, or a polymer to disperse well in water to 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 adhere materials to a substrate. In some embodiments, binder compositions are used to hold electrode components in place and adhere them to conductive metal parts to form electrodes. In some embodiments, the binder composition is comprised of a polymer. Such polymers can be referred to as "binder polymers." In some embodiments, the binder composition includes a polymer that is a copolymer. Such copolymers can be referred to as "binder copolymers." In some embodiments, the binder composition includes a liquid, where the liquid is an aqueous solvent. In some embodiments, the binder composition is substantially free of liquid. In other embodiments, the binder composition is free of liquid.

[0021] The term "dry" in the context of a mixture means that the mixture is substantially free of liquid or does not contain liquid. The term "substantially free of liquid" in the context of a mixture means that the mixture has a very low liquid content. In certain embodiments, "substantially free of liquid" means that the mixture has a liquid content of less than 1 wt.%, less than 0.8 wt.%, less than 0.6 wt.%, less than 0.5 wt.%, less than 0.4 wt.%, less than 0.3 wt.%, less than 0.2 wt.%, less than 0.15 wt.%, less than 0.1 wt.%, less than 0.05 wt.%, less than 0.03 wt.%, less than 0.02 wt.%, less than 0.015 wt.%, less than 0.01 wt.%, less than 0.1 wt.%, less than 0.075 wt.%, less than 0.05 wt.%, less than 0.025 wt.%, less than 0.02 wt.%, less than 0.015 wt.%, less than 0.0075 wt.%, less than 0.005 wt.%, less than 0.0025 wt.%, less than 0.002 wt.%, less than 0.0015 wt.%, or less than 0.001 wt.%, based on the total weight of the mixture.

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

[0023] The term "dry electrode mix" refers to a mixture of materials that can be used to form an electrode layer, wherein the mixture of materials is substantially liquid-free or liquid-free. In some embodiments, the dry electrode mix includes an electrode active material and a binder composition. In some embodiments, the dry electrode mix further includes 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 including a liquid vehicle. In some embodiments, the electrode slurry includes an electrode active material and a binder composition. In some embodiments, the electrode slurry further includes a conductive agent.

[0025] The term "particle size D50" refers to the volume-cumulative 50% size (D50), which is the particle size at the 50% point on a cumulative curve when the total volume is 100% and the cumulative curve is plotted to obtain a particle size distribution on a volume basis (i.e., the diameter of the particle at 50% (median) of the particle volume). Furthermore, with regard to the electrode active material of the present invention, particle size D50 refers to the volume-average particle size of secondary particles that may be formed by aggregation of primary particles, and in the case of an electrode active material consisting 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 moiety having one or more carbon-carbon double or triple bonds.

[0027] The term "alkyl" or "alkyl group" refers to a group of the general formula C n H 2n+1" 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, penthyl, isopentyl, neopentyl, hexyl, heptyl, and octyl. Examples of long-chain alkyl groups include nonyl and decyl groups. An alkyl group can be unsubstituted or substituted with one or more suitable substituents. Further, an alkyl group can 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 be branched or unbranched. Non-limiting examples of alkenyl 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 be branched or unbranched. Non-limiting examples of alkenyl include ethynyl, 3-methylpent-1-yn-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- or branched-chain saturated hydrocarbon. Examples of alkylene groups include methylene (-CH-), ethylene (-CHCH-), isopropylene (-CH(CH)CH-), and the like. Alkylene groups are optionally substituted with one or more substituents described herein.

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

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

[0032] The term "aryl" or "aryl group" refers to an organic radical derived from a monocyclic or polycyclic aromatic hydrocarbon by removing a hydrogen atom. Non-limiting examples of aryl groups include phenyl, naphthyl, benzyl, tolanyl, sexiphenyl, phenanthrenyl, anthracenyl, coronenyl, and tolanylphenyl. An aryl group can be unsubstituted or substituted with one or more suitable substituents.

[0033] The term "aliphatic" refers to a non-aromatic hydrocarbon or group derived therefrom. Some non-limiting 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 and optionally containing heteroatoms or substituents. Examples of such groups include, but are not limited to, phenyl, tolyl, biphenyl, o-terphenyl, m-terphenyl, p-terphenyl, naphthyl, anthryl, phenanthryl, pyrenyl, triphenyl, and derivatives thereof.

[0035] The term "substituted" refers to a compound or chemical moiety in which at least one hydrogen atom of the compound or chemical moiety has been replaced with a second chemical moiety. This second chemical moiety is known as a "substituent." Examples of substituents include halogen; alkyl; heteroalkyl; alkenyl; alkynyl; aryl, heteroaryl, hydroxyl; alkoxyl; amino; nitro; thiol; thioether; imine; cyano; amido; phosphonate; phosphinate; carboxyl; thiocarbonyl; sulfonyl; sulfonamido; acyl; formyl; acyloxy; alkoxycarbonyl; oxo; haloalkyl (e.g., trifluoromethyl); carbocyclic cycloalkyl (e.g., cyclopropyl, cyclobutyl, cyclopentyl, or cyclohexyl), which may be monocyclic or fused or non-fused polycyclic; heterocyclic, which may be monocyclic or fused or non-fused polycyclic (e.g., pyrrolidinyl, piperidinyl, piperazinyl, morpholinyl, or thiazinyl); monocyclic or fused or non-fused polycyclic aryl, 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, pyridazinyl, pyrimidinyl, benzimidazolyl, benzthiophenyl, or benzofuranyl). Amino (primary, secondary, or tertiary); o-lower alkyl; o-aryl, aryl, aryl lower alkyl; -COCH; -CONH; -OCHCONH; -NH; -SONH; -OCHF; -CF; -OCF; -NH(alkyl); -N(alkyl); -NH(aryl); -N(alkyl)(aryl); -N(aryl); -CHO-CO(alkyl); CO(aryl); CO(alkyl); and -CO(aryl); and such moieties may also be optionally substituted with fused ring structures or bridges, such as -OCHO-. These substituents may optionally be further substituted with substituents selected from such groups. All chemical groups disclosed herein may be substituted unless otherwise specified.

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

[0037] The term "monomer unit" refers to a constitutional unit contributed by a single monomer to the structure of a polymer.

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

[0039] The term "number average molecular weight" Mn of a polymer is mathematically defined as follows:

number

[0040] The term "weight average molecular weight" Mw of a polymer is mathematically defined as follows:

number

[0041] The term "polydispersity index" (PDI) of a polymer refers to the ratio of the weight average molecular weight to the number average molecular weight (i.e., Mw / Mn) of the polymer. It is a measure of the distribution of molecular weights 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 materials throughout a mixture. Any conventional homogenizer can be used in the methods disclosed herein. Some non-limiting examples of homogenizers include agitator mixers, planetary mixers, tumblers, and mills.

[0043] The term "tumbler" refers to a device that can be used to mix or stir different materials to produce a homogeneous mixture, where the device consists of a container that rotates about a fixed axis and contains the materials to be stirred. In some embodiments, the tumbler does not include an impeller. In some embodiments, the tumbler includes free-moving components, such as balls or pebbles, to reduce particle agglomeration. Rotational speed can be expressed in revolutions per minute (rpm), which refers to the number of revolutions 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 is comprised of one or more impellers that rotate about a fixed axis within a vessel. The term "planetary mixer" refers to a device that can be used to mix or agitate different materials to produce a homogeneous mixture, and is comprised of two or more impellers that rotate about their own axes while continuously rotating within a vessel. In some embodiments, the 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 materials, including mixers that can be used to mix or agitate different materials to produce a homogeneous mixture. Particle size can be reduced by abrading the particles using a variety of methods, including, but not limited to, the surface of a container, pressurized gas, or heavy spheres.

[0046] The term "applying" refers to the act of laying or spreading a substance on a surface.

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

[0048] The term "molding press" refers to an apparatus that uses mechanical force to generate high pressure to form a coating or pellet from a powder using one or more dies. In some embodiments, this force can be provided by a pneumatic or hydraulic piston. The term "tablet press" refers to a molding press that forms small pellets from a powder.

[0049] "Transfer coating" refers to a process for forming large-area films on hard or soft substrates. Rather than applying the slurry directly to the substrate to form a coating layer, the slurry is first applied to a release film. The release film with the coating layer then contacts the substrate, forming a coating layer on the substrate. A "transfer coater" is a device capable of performing transfer coating.

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

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

[0052] The term "room temperature" refers to a room temperature of about 18°C ​​to about 30°C, e.g., 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 about 20°C ± 1°C, or ± 2°C, or ± 3°C. In other embodiments, room temperature refers to a temperature of about 22°C or about 25°C.

[0053] The term "specific humidity" of an area refers to the mass of water vapor present per unit mass of air in that area.

[0054] The term "solids" refers to the amount of non-volatile material in a mixture that remains after evaporation. The term "solids" in reference to a mixture refers to this non-volatile material. The term "liquid content" refers to the amount of material that has evaporated from the mixture. The term "liquid portion" in reference to a mixture refers to this evaporated material. The sum of the solids and liquid content of a mixture adds up to the total mass of the mixture. The solids and / or liquid content of a mixture are often expressed as a fraction or percentage of the total mass of the mixture. If a mixture does not contain any liquid, the solids content of the mixture is 100% and the liquid content is 0%.

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

[0056] The term "C-rate" refers to the charge or discharge rate of a cell or battery, and its total capacity in Ah or mAh. For example, 1C means using the entire charge in 1 hour, 0.1C means using 10% of the energy in 11 hours or using all the energy in 10 hours, and 5C means using all the energy in 12 minutes.

[0057] "Ampere-hour (Ah)" is a unit of measurement for the amount of electrical energy stored in a battery. For example, a 1Ah battery can supply a current of 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 the unit of electrical energy stored in a battery, and is 1 / 1000 of an Ampere-hour.

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

[0059] In the description that follows, all numerical values ​​disclosed herein are approximate, regardless of whether the word "about" or "approximately" is used in connection therewith. They can vary by 1%, 2%, 5%, and in some cases 10 to 20%. Whenever a numerical range with a lower limit, R L and an upper limit, R R , is disclosed, any numerical value falling within that range is specifically disclosed. In particular, numerical values ​​within the following range are specifically disclosed: R = R L + (k) * (R R - R L ), where k is a variable ranging from 0% to 100%. Additionally, any numerical range defined by two R numbers as defined above is also specifically disclosed.

[0060] As used herein, all references to the singular include references to the plural 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 coating the electrode slurry onto a current collector and drying it.

[0062] Electrode slurries are commonly made with PVDF as the binder and NMP as the solvent. However, the use of NMP poses significant environmental, health, and safety risks. Therefore, the use of NMP requires the installation of a vapor recovery system, which is costly. Therefore, a water-based electrode slurry, consisting of a water-compatible binder polymer and an aqueous solvent, has been proposed as a safer and more environmentally friendly method.

[0063] However, such water-compatible polymers are often in the form of wet binder compositions consisting of the polymer and a large amount of aqueous solvent from the polymer manufacturing process, which poses logistical challenges as the large amount of aqueous solvent makes it difficult to store or transport the wet binder compositions in significant quantities.

[0064] For water-insoluble polymers such as PVDF, binder compositions that are substantially water-free are readily available. Indeed, such binder compositions have been successfully incorporated into dry electrode mixes. However, converting a wet binder composition to a dry binder composition can be challenging because the water-compatible polymer undergoes irreversible morphological changes upon dehydration, potentially resulting in poor binder performance even upon rehydration. Due to the inherent affinity of the water-compatible polymer for the aqueous solvent in the binder composition, reducing the liquid content of the wet binder composition by removing the aqueous solvent can be challenging.

[0065] Disclosed herein are binder compositions comprising a water-compatible copolymer, the binder composition having 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 a polymerization process. In some embodiments, the processed binder composition is a dry binder composition, i.e., a binder composition that is substantially free of liquid or free of 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. The liquid portion of a semi-dry binder composition is referred to herein 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 via polymerization of a monomer, polymer, or monomer-polymer complex dispersed in an aqueous medium, where the polymerization is initiated by free radicals generated by a water-soluble free radical initiator. The polymerization process can use any suitable reaction conditions as long as it successfully forms the copolymer.

[0067] The aqueous medium in the polymerization acts as a solvent for the free radical initiator and 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), DO, 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 minor component is about 51:49 to about 99:1. Any water-miscible or volatile solvent can be used as a minor component of the aqueous medium. Some non-limiting examples of water-miscible 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, gamma-valerolactone (GVL), furfuryl alcohol, methyl lactate, ethyl lactate, diethanolamine, dimethylacetamide (DMSO), dimethylacetamide (DMAc), dimethylformamide (DMF), N-methylpyrrolidone (NMP), dihydrolevoglucosenone (Cyrene), and the like. TM ), N,N'-dimethylpropyleneurea (DMPU), and dimethylisosorbide (DMI). In some embodiments, no trace components are present in the aqueous medium.

[0070] In some embodiments, the water-compatible copolymer comprises structural units (a) derived from an acid group-containing monomer, wherein the acid group is selected from the group consisting of carboxylic acid, sulfonic acid, sulfuric acid, phosphonic acid, phosphoric acid, nitric acid, 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 of the salts of the above acids.

[0071] In some embodiments, the carboxylic acid is acrylic acid, methacrylic acid, crotonic acid, 2-butyl crotonate, cinnamic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, itaconic anhydride, tetraconic acid, or a combination thereof. In certain embodiments, the carboxylic acid is 2-ethylacrylic acid, isocrotonic acid, cis-2-pentenoic acid, trans-2-pentenoic acid, angelic acid, tiglic 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 ... propylacrylic acid, 2,3-diethylacrylic acid, 3,3-diethylacrylic acid, 3-methyl-3-hexylacrylic acid, 3-methyl-3-tert-butylacrylic acid, 2-methyl-3-pentylacrylic acid, 3-methyl-2-hexenoic acid, 4-ethyl-2-hexenoic acid, 2-methylethyl ester, 3-tertylacrylic acid, 2,3-dimethyl-3-ethylacrylic acid, 3,3-dimethyl-2-ethylacrylic acid, 3-methyl-3-isopropylacrylic acid, 2-methyl-3-isopropylacrylic acid, trans-2-octenoic acid, cis-2-octenoic acid, trans-2-decenoic acid, α-acetoxyacrylic acid, β-trans-allyloxyacrylic 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, methylmaleic anhydride, dimethylmaleic 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-allyloxy-2-hydroxy-1-propanesulfonic acid, or a combination thereof.

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

[0074] In some embodiments, the phosphonic acid is vinylphosphonic acid, arylphosphonic acid, vinylbenzylphosphonic acid, acrylamidoalkylphosphonic acid, methacrylamidoalkylphosphonic acid, acrylamidoalkyldiphonic 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, the phosphoric acid is selected from the group consisting of mono(2-acryloyloxyethyl)phosphate, mono(2-methacryloyloxyethyl)phosphate, diphenyl(2-acryloyloxyethyl)phosphate, diphenyl(2-methacryloyloxyethyl)phosphate, phenyl(2-acryloyloxyethyl)phosphate, methacrylatephosoxyethyl, 3-chloro-2-phosphoryloxypropyl methacrylate, phosphoryloxypoly(ethylene glycol) monomethacrylate, phosphoryloxypoly(propylene glycol) methacrylate, (meth)acryloyloxyethyl phosphate, (meth)acryloyloxypropyl ... (meth)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 trimetaphosphate, vinyl hydrogen trimetaphosphate, isopentenyl phosphate, isopentenyl pyrophosphate, or a combination thereof, wherein (meth)acryloyl- represents acryloyl- or methacrylylol-.

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

[0077] In some embodiments, the proportion of structural unit (a) in the water compatible copolymer is 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%, about 10 mol% to about 75 mol%, about 10 mol% to about 70 mol%, about 10 mol% to about 65 mol%, about 10 mol% to about 60 mol%, about 10 mol% to about 55 mol%, about 10 mol% to about 50 mol%, about 10 mol% to about 45 mol%, about 10 mol% to about 40 mol%, about 10 mol% to about 35 mol%, about 10 mol% to about 30 mol%, about 15 mol% to about 95 mol%, about 15 mol% to about 90 mol%, about 15 mol% to about 85 mol%, about 15 mol% to about 80 mol%, about 15 mol% to about 75 mol%, about 15 mol% to about 70 mol%, about 15 mol% to about 65 mol%, about 15 mol% to about 60 mol%, about 15 mol% to about 55 mol%, about 15 mol% to about 45 mol%, about 15 mol% to about 35 mol%, about 20 mol% to about 95 mol%, about 20 mol% to about 90 mol%, about 20 mol% to about 85 mol%, about 20 mol% to about 80 mol%, about 20 mol% to about 75 mol%, about 20 mol% to about 70 mol%, about 20 mol% to about 65 mol%, about 20 mol% to about 60 mol%, about 20 mol% to about 55 mol%, about 20 mol% to about 50 mol%, about 20 mol% to about 45 mol%, about 20 mol% to about 40 mol%, about 25 mol% to about 95 mol%, about 25 mol% to about 90 mol%, about 25 mol% to about 85 mol%, about 25 mol% to about 80 mol%, about 25 mol% to about 75 mol%, about 25 mol% to about 70 mol%, about 25 mol% to about 65 mol%, about 25 mol% to about 60 mol%, about 25 mol% to about 55 mol%, about 25 mol% to about 50 mol%, about 25 mol% to about 45 mol%,About 30 mol% to about 95 mol%, about 30 mol% to about 90 mol%, about 30 mol% to about 85 mol%, about 30 mol% to about 80 mol%, about 30 mol% to about 75 mol%, about 30 mol% to 70 mol%, about 30 mol% to 65 mol%, about 30 mol% to 60 mol%, about 30 mol% to about 55 mol%, about 30 mol% to about 50 mol%, about 35 mol% to 95 mol%, about 35 mol% to about 90 mol%, about 35 mol% to about 85 mol%, about 35 mol% to about 80 mol%, about 35 mol% to about 75 mol%, about 35 mol% to about 70 mol%, about 35 mol% to about 65 mol%, about 35 mol% to about 60 mol%, about 35 mol% to about 55 mol%, about 40 mol% to about 95 mol%, about 40 mol% to about 90 mol%, about 40 mol% to 85 mol%, about 40 mol% to about 80 mol%, about 40 mol% to about 75 mol%, about 40 mol% to about 70 mol%, about 40 mol% to about 65 mol%, about 40 mol% to about 60 mol%, about 40 mol% to about 75 mol%, about 45 mol% mol% to about 95 mol%, about 45 mol% to about 90 mol%, about 45 mol% to about 85 mol%, about 45 mol% to about 80 mol%, about 45 mol% to about 75 mol%, about 45 mol% to about 70 mol%, about 45 mol% to about 65 mol%, about 50 mol% to about 95 mol%, about 50 mol% to about 90 mol%, about 50 mol% to about 85 mol%, about 50 mol% to about 80 mol%, about 50 mol% to about 75 mol%, about 50 mol% to about 70 mol%, about 55 mol% to 95 mol%, about 55 mol% to about 55 mol%, % to 90 mol%, about 55 mol% to 85 mol%, about 55 mol% to about 80 mol%, about 55 mol% to about 75 mol%, about 60 mol% to about 95 mol%, about 60 mol% to about 90 mol%, about 60 mol% to about 85 mol%, about 60 mol% to about 80 mol%, about 65 mol% to about 95 mol%, about 65 mol% to about 85 mol%, about 70 mol% to about 95 mol%, about 75 mol% to about 90 mol%, about 80 mol% to about 95 mol%, or about 80 mol% to about 90 mol%.

[0078] In some embodiments, the proportion of structural unit (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%, about 22 mol%, about 23 mol%, about 24 mol%, about 25 mol%, about 26 mol%, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mol%, about 33 mol%, about 34 mol%, about 35 mol%, about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, about 44 mol%, about 45 mol%, about 46 mol%, about 47 mol%, about 48 mol%, about 49 mol%, about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%, about 63 mol%, about 64 mol%, about 65 mol%, about 66 mol%, about 67 mol%, about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about About 22 mol%, about 23 mol%, about 24 mol%, about 25 mol%, about 26 mol%, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mol%, about 33 mol%, about 34 mol%, about 35 mol%, about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, about 44 mol%, about 45 mol%, about 46 mol% , about 47 mol%, about 48 mol%, about 49 mol%, about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%, about 63 mol%, about 64 mol%, about 65 mol%, about 66 mol%, about 67 mol%, about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol %, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about 76 mol%, about 77 mol%, about 78 mol%, about 79 mol%, about 80 mol%, about 81 mol%, about 82 mol%, about 83 mol%, about 84 mol%, about 85 mol%, about 86 mol%, about 87 mol%, about 88 mol%, about 89 mol%, about 90 mol%, about 91 mol%, about 92 mol%, about 93 mol%, about 94 mol% or about 95 mol%.

[0079] In some embodiments, the proportion of structural unit (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 unit (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 monomer is 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, N-(propoxymethyl)methacrylamide, N-(butoxymethyl)methacrylamide, N,N-dimethylaminopropyl methacrylamide, N,N-dimethylaminoethyl methacrylamide, N,N-dimethylol methacrylamide, diaketone methacrylamide, diacetone acrylamide, methacryloylmorpholine, N-hydroxyl methacrylamide, N-methoxymethyl acrylamide, N-methoxymethyl methacrylamide, N,N'-methylenebisacrylamide (MBA), N-hydroxymethyl acrylamide or a combination thereof.

[0082] In some embodiments, the hydroxyl group-containing monomer is a C1-C 20 Alkyl or C5-C 20 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 alcohol, or a combination thereof.

[0083] In some embodiments, the proportion of structural unit (b) in the water compatible copolymer is 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 50 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 55 mol%, from about 5 mol% to about 50 ...0 mol%, from about 5 mol% to about 50 mol%, from about 5 mol% to about 50 to about 30 mol%, about 5 mol% to about 25 mol%, about 10 mol% to about 95 mol%, about 10 mol% to about 90 mol%, about 10 mol% to about 85 mol%, about 10 mol% to about 80 mol%, about 10 mol% to about 75 mol%, about 10 mol% to about 70 mol%, about 10 mol% to about 65 mol%, about 10 mol% to about 60 mol%, about 10 mol% to about 55 mol%, about 10 mol% to about 50 mol%, about 10 mol% to about 45 mol%, about 10 mol% to about 40 mol%, about 10 mol% to about 35 mol%, about 10 mol% to about 30 mol%, about 15 mol% to about 95 mol% , about 15 mol% to about 90 mol%, about 15 mol% to about 85 mol%, about 15 mol% to about 80 mol%, about 15 mol% to about 75 mol%, about 15 mol% to about 70 mol%, about 15 mol% to about 65 mol%, about 15 mol% to about 60 mol%, about 15 mol% to about 55 mol%, about 15 mol% to about 45 mol%, about 15 mol% to about 35 mol%, about 20 mol% to 95 mol%, about 20 mol% to 90 mol%, about 20 mol% to about 85 mol%, about 20 mol% to about 80 mol%, about 20 mol% to about 75 mol%, about 20 mol% to about 70 mol%, about 20 mol% to about about 65 mol%, about 20 mol% to about 60 mol%, about 20 mol% to about 55 mol%, about 20 mol% to about 50 mol%, about 20 mol% to about 45 mol%, about 20 mol% to about 40 mol%, about 25 mol% to about 95 mol%, about 25 mol% to about 90 mol%, about 25 mol% to about 85 mol%, about 25 mol% to about 80 mol%, about 25 mol% to about 75 mol%, about 25 mol% to about 70 mol%, about 25 mol% to about 60 mol%, about 25 mol% to about 55 mol%, about 25 mol% to about 50 mol%, about 25 mol% to about 45 mol%, about 30 mol% to about 95 mol%,about 30 mol% to about 90 mol%, about 30 mol% to about 85 mol%, about 30 mol% to about 80 mol%, about 30 mol% to about 75 mol%, about 30 mol% to 70 mol%, about 30 mol% to 65 mol%, about 30 mol% to about 60 mol%, about 30 mol% to about 55 mol%, about 35 mol% to 95 mol%, about 35 mol% to about 90 mol%, about 35 mol% to about 85 mol%, about 35 mol% to about 80 mol%, about 35 mol% to about 75 mol%, About 35 mol% to about 70 mol%, about 35 mol% to about 65 mol%, about 35 mol% to about 60 mol%, about 35 mol% to about 55 mol%, about 40 mol% to about 95 mol%, about 40 mol% to about 90 mol%, about 40 mol% to about 85 mol%, about 40 mol% to about 80 mol%, about 40 mol% to 75 mol%, about 40 mol% to about 70 mol%, about 40 mol% to about 65 mol%, about 45 mol% to about 95 mol%, about 45 mol% to about 90 mol%, about 40 mol% to about 95 ... 5 mol% to about 85 mol%, about 45 mol% to about 80 mol%, about 45 mol% to about 75 mol%, about 45 mol% to about 70 mol%, about 45 mol% to about 65 mol%, about 50 mol% to about 95 mol%, about 50 mol% to about 90 mol%, about 50 mol% to about 85 mol%, about 50 mol% to about 80 mol%, about 50 mol% to about 75 mol%, about 50 mol% to about 70 mol%, about 55 mol% to 95 mol%, 55 mol% to 90 mol%, about 55 mol% to about 55 mol% % to 85 mol%, about 55 mol% to about 80 mol%, about 55 mol% to about 75 mol%, about 60 mol% to about 95 mol%, about 60 mol% to about 90 mol%, about 60 mol% to about 85 mol%, about 60 mol% to about 80 mol%, about 65 mol% to about 95 mol%, about 65 mol% to about 85 mol%, about 70 mol% to about 95 mol%, about 75 mol% to about 90 mol%, about 80 mol% to about 95 mol%, or about 80 mol% to about 90 mol%.

[0084] In some embodiments, the proportion of structural unit (b) 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%, about 22 mol%, about 23 mol%, about 24 mol%, about 25 mol%, about 26 mol%, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mol%, about 33 mol%, about 34 mol%, about 35 mol%, about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, about 44 mol%, about 45 mol%, about 46 mol%, about 47 mol%, about 48 mol%, about 49 mol%, about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%, about 63 mol%, about 64 mol%, about 65 mol%, about 66 mol%, about 67 mol%, about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about %, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mol%, about 33 mol%, about 34 mol%, about 35 mol%, about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, about 44 mol%, about 45 mol%, about 46 mol%, about 47 mol%, about 48 mol%, about 49 mol%, about 49 mol%, about 47 mol%, about 47 mol%, about 48 mol%, about 48 mol%, and about 47 mol%. About 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%, about 63 mol%, about 64 mol%, about 65 mol%, about 66 mol%, about 67 mol%, about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol% , about 74 mol%, about 75 mol%, about 76 mol%, about 75 mol%, about 77 mol%, about 78 mol%, about 79 mol%, about 80 mol%, about 81 mol%, about 82 mol%, about 83 mol%, about 84 mol%, about 85 mol%, about 86 mol%, about 87 mol%, about 88 mol%, about 89 mol%, about 90 mol%, about 91 mol%, about 92 mol%, about 93 mol%, about 94 mol%, or about 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 comprises an α,β-ethylenically unsaturated nitrile monomer. 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 a C-C 20 Alkyl acrylate, C1-C 20In some embodiments, the ester group-containing monomer is 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 a combination thereof. In some embodiments, the ester group-containing monomer is cyclohexyl acrylate, cyclohexyl 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 a vinyl ether, an aryl ether, an aryl vinyl ether, an aryl glycidyl ether, a 2H-hexafluoroisopropyl aryl ether, a hydroxypolyethoxy(10) aryl ether, an aryl phenethyl ether, an ethyl vinyl ether, a propyl vinyl ether, an N-butyl vinyl ether, or a combination thereof.

[0090] In some embodiments, the epoxy group-containing monomer is 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 crotonate, 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-pentenoate, 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, oct-2-enal, 2-methylpent-2-enal, 4-methylpent-3-enonone, oct-1-en-3-one, 2-pentylbut-1-en-3-one, or a combination thereof.

[0092] In some embodiments, the fluorine-containing monomer is C-C 20 The acrylate or methacrylate containing alkyl group, or a combination thereof, wherein the monomer comprises at least one fluorine atom.In some embodiments, the fluorine-containing monomer is perfluoroalkyl acrylate such as perfluorododecyl acrylate, perfluoro n-octyl acrylate, perfluoro n-butyl acrylate, perfluorohexyl ethyl acrylate and perfluorooctyl ethyl acrylate; perfluoroalkyl methacrylate such as perfluorododecyl methacrylate, perfluoro n-octyl methacrylate, perfluoro n-butyl methacrylate, perfluorohexyl ethyl methacrylate and perfluorooctyl ethyl methacrylate; perfluorooxyalkyl acrylate such as perfluorododecyl acrylate and perfluorodecyl ethyl acrylate, for example, perfluorooxyalkyl methacrylate such as perfluorododecyl ethyl acrylate and perfluorodecyl ethyl acrylate, or a combination thereof.In some embodiments, the fluorine-containing monomer is C1-C 20 and a carboxylate containing an alkyl group and a fluorine atom; wherein the carboxylate is selected from the group consisting of crotonate, maleate, fumarate, itaconate, or a combination 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 a combination thereof.

[0093] In some embodiments, the proportion of structural unit (c) in the water compatible copolymer is 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 50 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 55 mol%, from about 5 mol% to about 50 ... to about 30 mol%, about 5 mol% to about 25 mol%, about 10 mol% to about 95 mol%, about 10 mol% to about 90 mol%, about 10 mol% to about 85 mol%, about 10 mol% to about 80 mol%, about 10 mol% to about 75 mol%, about 10 mol% to about 70 mol%, about 10 mol% to about 65 mol%, about 10 mol% to about 60 mol%, about 10 mol% to about 55 mol%, about 10 mol% to about 50 mol%, about 10 mol% to about 45 mol%, about 10 mol% to about 40 mol%, about 10 mol% to about 35 mol%, about 10 mol% to about 30 mol%, about 15 mol% to about 95 mol% , about 15 mol% to about 90 mol%, about 15 mol% to about 85 mol%, about 15 mol% to about 80 mol%, about 15 mol% to about 75 mol%, about 15 mol% to about 70 mol%, about 15 mol% to about 65 mol%, about 15 mol% to about 60 mol%, about 15 mol% to about 55 mol%, about 15 mol% to about 45 mol%, about 15 mol% to about 35 mol%, about 20 mol% to 95 mol%, about 20 mol% to 90 mol%, about 20 mol% to about 85 mol%, about 20 mol% to about 80 mol%, about 20 mol% to about 75 mol%, about 20 mol% to about 70 mol%, about 20 mol% to about about 65 mol%, about 20 mol% to about 60 mol%, about 20 mol% to about 55 mol%, about 20 mol% to about 50 mol%, about 20 mol% to about 45 mol%, about 20 mol% to about 40 mol%, about 25 mol% to about 95 mol%, about 25 mol% to about 90 mol%, about 25 mol% to about 85 mol%, about 25 mol% to about 80 mol%, about 25 mol% to about 75 mol%, about 25 mol% to about 70 mol%, about 25 mol% to about 65 mol%, about 25 mol% to about 60 mol%, about 25 mol% to about 55 mol%, about 25 mol% to about 50 mol%, about 25 mol% to about 45 mol%,about 30 mol% to about 95 mol%, about 30 mol% to about 90 mol%, about 30 mol% to about 85 mol%, about 30 mol% to about 80 mol%, about 30 mol% to about 75 mol%, about 30 mol% to 70 mol%, about 30 mol% to 65 mol%, about 30 mol% to about 60 mol%, about 30 mol% to about 55 mol%, about 35 mol% to 95 mol%, about 35 mol% to about 90 mol%, about 35 mol% to about 85 mol%, about 35 mol% to about 80 mol%, about 35 mol% to about 75 mol%, about 35 mol% to about 70 mol%, about 35 mol% to about 65 mol%, about 35 mol% to about 60 mol%, about 35 mol% to about 55 mol%, about 40 mol% to about 95%, about 40% to about 90%, about 40% to 85%, about 40% to about 80%, about 40% to 75%, about 40% to to about 70%, about 40% to about 65%, about 45% to about 95%, about 45% to about 90%, about 45% to about 85%, about 45% to about 80%, about 45% to about 75%, about 45% to about 70%, about 45% to about 65%, about 50% to about 95%, about 50% to about 90%, about 50% to about 85%, about 50% to about 80%, about 50% to about 75%, about 50% to about 70%, about 55% % to 95%, 55% to 90%, about 55% to 85%, about 55% to about 80%, about 55% to about 75%, about 60% to about 95%, about 60% to about 90%, about 60% to about 85%, about 60% to about 80%, about 65% to about 95%, about 65% to about 85%, about 70% to about 95%, about 75% to about 90%, about 80% to about 95%, or about 80% to about 90%.

[0094] In some embodiments, the proportion of structural unit (c) 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%, about 22 mol%, about 23 mol%, about 24 mol%, about 25 mol%, about 26 mol%, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mol%, about 33 mol%, about 34 mol%, about 35 mol%, about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, about 44 mol%, about 45 mol%, about 46 mol%, about 47 mol%, about 48 mol%, about 49 mol%, about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%, about 63 mol%, about 64 mol%, about 65 mol%, about 66 mol%, about 67 mol%, about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about About 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, about 44 mol%, about 45 mol%, about 46 mol%, about 47 mol%, about 48 mol%, about 49 mol%, about 49 mol%, about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%, about 63 mol%, about 64 mol%, about 65 mol%, about 66 mol%, about 67 mol%, about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about 76 mol%, about 75 mol%, about 77 mol%, about 78 mol%, about 79 mol%, about 80 mol%, about 81 mol%, about 82 mol%, about 83 mol%, about 84 mol%, about 85 mol%, about 86 mol%, about 87 mol%, about 88 mol%, about 89 mol%, about 90 mol%, about 91%, about 92%, about 93%, about 94% or about 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 an olefin. Any hydrocarbon having at least one carbon-carbon double bond may be used as the olefin. In some embodiments, the olefin is a C2-C 20 Aliphatic compounds, C8-C containing vinylic unsaturation 20 Aromatic or cyclic compounds, C4-C 40and dienes, and combinations thereof. In some embodiments, the olefin is 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, norbornaene, ethylidenenorbornene, cyclopentene, cyclohexene, dicyclopentadiene, cyclooctene, or a combination thereof. In some embodiments, the water-compatible copolymer does not contain structural units derived from an olefin. 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, norbornaene, ethylidenenorbornene, cyclopentene, cyclohexene, dicyclopentadiene, or cyclooctene.

[0097] The conjugated diene comprises an olefin. In some embodiments, the conjugated diene comprises a C-C 40 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-chloro-1,3-butadiene; substituted linear conjugated pentadiene; substituted branched conjugated hexadienes; and combinations thereof. In some embodiments, the water-compatible copolymer is selected from the group consisting of C4-C 40It does not contain structural units derived from dienes; aliphatic conjugated dienes (in particular, 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, or 2-chloro-1,3-butadiene); substituted linear conjugated pentadiene; or substituted branched conjugated hexadienes.

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

[0099] Copolymers with the above structural unit ratios have excellent binder properties. Furthermore, because such copolymers are compatible with water and disperse well in aqueous solvents, they are easily processed when used in aqueous electrode slurries. Furthermore, batteries using these water-soluble copolymers in electrodes have excellent capacity and electrochemical performance.

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

[0101] In some embodiments, the solids portion of the reaction mixture is from about 1 wt % to about 20 wt %, from about 2 wt % to about 20 wt %, from about 3 wt % to about 20 wt %, from about 4 wt % to about 20 wt %, from about 5 wt % to about 20 wt %, from about 6 wt % to about 20 wt %, from about 7 wt % to about 20 wt %, from about 8 wt % to about 20 wt %, from about 9 wt % to about 20 wt %, from about 10 wt % to about 20 wt %, from about 1 wt % to about 18 wt %, from about 2 wt % to about 18 wt %, from about 3 wt % to about 18 wt %, from about 4 wt % to about 18 wt %, from about 5 wt % to about 20 wt %, based on the total weight of the reaction mixture. to about 18% by weight, about 6% to about 18% by weight, about 7% to about 18% by weight, about 8% to about 18% by weight, about 9% to about 18% by weight, about 10% to about 18% by weight, about 1% to about 15% by weight, about 2% to about 15% by weight, about 3% to about 15% by weight, about 4% to about 15% by weight, about 5% to about 15% by weight, about 6% to about 15% by weight, about 7% to about 15% by weight, about 8% to about 15% by weight, about 1% to about 12% by weight, about 2% to about 12% by weight, about 3% to about 12% by weight, about 4% to about 15% by weight. About 5% to about 12% by weight, about 1% to about 10% by weight, about 2% to about 10% by weight, about 3% to about 10% by weight, about 4% to about 10% by weight, or about 5% to about 10% by weight.

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

[0103] When the weight average molecular weight of the water-compatible copolymer is within the range specified below, an electrode layer made of the copolymer has good adhesive strength, and a 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 from about 10,000 g / mol to about 1,000,000 g / mol, from about 10,000 g / mol to about 800,000 g / mol, from about 10,000 g / mol to about 500,000 g / mol, from about 10,000 g / mol to about 400,000 g / mol, from about 10,000 g / mol to about 300,000 g / mol, from about 10,000 g / mol to about 200,000 g / mol, from about 10,000 g / mol to about 180,000 g / mol, from about 10,000 g / mol to about 150,000 g / mol, or from about 10,000 g / mol to about 200,000 g / mol. g / mol to about 120,000 g / mol, about 10,000 g / mol to about 100,000 g / mol, about 10,000 g / mol to about 80,000 g / mol, about 10,000 g / mol to about 50,000 g / mol, about 50,000 g / mol to about 1,000,000 g / mol, about 50,000 g / mol to about 800,000 g / mol, about 50,000 g / mol to about 500,000 g / mol, about 50,000 g / mol to about 400,000 g / mol, about 50,000 g / mol to about 300,000 g / mol, about 50,000 g / mol to about 200,000 g / mol g / mol, about 50,000 g / mol to about 180,000 g / mol, about 50,000 g / mol to about 150,000 g / mol, about 100,000 g / mol to about 1,000,000 g / mol, about 100,000 g / mol to about 800,000 g / mol, about 100,000 g / mol to about 500,000 g / mol, about 100,000 g / mol to about 400,000 g / mol, about 100,000 g / mol to about 300,000 g / mol, about 100,000 g / mol to about 200,000 g / mol, about 100,000 g / mol to about 180,000 g / mol, about 100,000 g / mol to about 150,000 g / mol, about 120,000 g / mol to about 1,000,000 g / mol, about 120,000 g / mol to about 800,000 g / mol, about 120,000 g / mol to about 600,000 g / mol, about 120,000 g / mol to about 500,000 g / mol, about 120,000 g / mol to about 400,000 g / mol, about 120,000 g / mol to about 300,000 g / mol, about 120,000 g / mol to about 200,000 g / mol, about 120,000 g / mol to about 190,000 g / mol, about 120,000g / mol to about 180,000, g / mol , about 140,000 g / mol to about 1,000,000 g / mol, about 140,000 g / mol to about 800,000 g / mol, about 140,000 g / mol to about 500,000 g / mol, about 140,000 g / mol to about 400,000 g / mol, about 140,000 g / mol to about 300,000 g / mol, about 140,000 g / mol to 200,000 g / mol, about 140,000 g / mol to 190,000 g / mol, about 140,000 g / mol to about 180,000 g / mol, about 150,000 g / mol to about 1,000,000 g / mol, about 150,000 g / mol to about 800,000 g / mol, about 150,000 g / mol to about 500,000 g / mol, about 150,000 g / mol to about 400,000 g / mol, about 15 0,000 g / mol to about 300,000 g / mol, about 150,000 g / mol to about 200,000 g / mol, about 150,000 g / mol to about 190,000 g / mol, about 150,000 g / mol to about 180,000 g / mol, about 200,000 g / mol to about 1,000,000 g / mol, about 200,000 g / mol to about 800,000 g / mol, about 200 ,000 g / mol to about 600,000 g / mol, about 200,000 g / mol to about 500,000 g / mol, about 200,000 g / mol to about 400,000 g / mol, about 500,000 g / mol to about 1,000,000 g / mol, about 500,000 g / mol to about 900,000 g / mol, or about 500,000 g / mol to about 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, or less than 170,000 g / mol. , 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. greater than 130,000 g / mol, greater than 140,000 g / mol, greater than 150,000 g / mol, greater than 160,000 g / mol, greater than 170,000 g / mol, greater than 180,000 g / mol, greater than 190,000 g / mol, greater than 200,000 g / mol, greater than 300,000 g / mol, greater than 400,000 g / mol, greater than 500,000 g / mol, greater than 600,000 g / mol or greater than 700,000 g / mol.

[0106] In some embodiments, the number average molecular weight of the water compatible copolymer is from about 10,000 g / mol to about 500,000 g / mol, from about 10,000 g / mol to about 300,000 g / mol, from about 10,000 g / mol to about 200,000 g / mol, from about 10,000 g / mol to about 100,000 g / mol, from about 10,000 g / mol to about 90,000 g / mol, from about 10,000 g / mol to about 80,000 g / mol, from about 10,000 g / mol to about 70,000 g / mol, from about 10,000 g / mol to about 60,000 g / mol, or from about 10,000 g / mol to about 50,000 g / mol, about 10,000 g / mol to about 40,000 g / mol, about 20,000 g / mol to about 500,000 g / mol, about 20,000 g / mol to about 300,000 g / mol, about 20,000 g / mol to about 200,000 g / mol, about 20,000 g / mol to about 100,000 g / mol, about 20,000 g / mol to about 90,000 g / mol, about 20,000 g / mol to about 80,000 g / mol, about 20,000 g / mol to about 70,000 g / mol, about 20,000 g / mol to about 60,000 g / mol, about 20,000 g / mol / mol to about 50,000 g / mol, about 30,000 g / mol to about 500,000 g / mol, about 30,000 g / mol to about 300,000 g / mol, about 30,000 g / mol to about 200,000 g / mol, about 30,000 g / mol to about 100,000 g / mol, about 30,000 g / mol to about 90,000 g / mol, about 30,000 g / mol to about 80,000 g / mol, about 30,000 g / mol to about 70,000 g / mol, about 40,000 g / mol to about 500,000 g / mol, about 40,000 g / mol to about 300,000 g / mol, about 40,000 g / mol to about 200,000 g / mol, about 40,000 g / mol to about 100,000 g / mol, about 40,000 g / mol to about 90,000 g / mol, about 40,000 g / mol to about 80,000 g / mol, about 40,000 g / mol to about 70,000 g / mol, about 50,000 g / mol to about 500,000 g / mol, about 50,000 g / mol to about 300,000 g / mol, about 50,000 g / mol to about 200,000 g / mol, about 50,000 g / mol to about 100,000 g / mol, about 50,000 g / mol to about 90,000 g / mol, about 50,000 g / mol to about 80,000 g / mol, about 60,000 g / mol to about 500,000 g / mol, about 60,000 g / mol to about 300,000 g / mol, about 60,000 g / mol to about 200,000 g / mol, about 60,000 g / mol to about 150,000 g / mol, about 60,000 g / mol to about 100 ,000 g / mol, about 60,000 g / mol to about 90,000 g / mol, about 70,000 g / mol to about 500,000 g / mol, about 70,000 g / mol to about 300,000 g / mol, about 70,000 g / mol to about 200,000 g / mol, about 70,000 g / mol to about 150,000 g / mol, about 70,000 g / mol to about 10 0,000 g / mol, about 80,000 g / mol to about 500,000 g / mol, about 80,000 g / mol to about 300,000 g / mol, about 80,000 g / mol to about 200,000 g / mol, about 80,000 g / mol to about 150,000 g / mol, about 90,000 g / mol to about 500,000 g / mol, about 90,000 g / mol to about 300,000 g / mol, about 90,000 g / mol to about 200,000 g / mol, about 90,000 g / mol to about 150,000 g / mol, about 100,000 g / mol to about 500,000 g / mol, about 100,000 g / mol to about 300,000 g / mol, or about 100,000 g / mol to about 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 from about 1 to about 20, from about 1 to about 15, from about 1 to about 10, from about 1 to about 5, from about 1 to about 4.8, from about 1 to about 4.2, from about 1 to about 4, from about 1 to about 3.8, from about 1 to about 3.5, from about 1 to about 3.2, from about 1.2 to about 20, from about 1.2 to about 15, from about 1.2 to about 10, from about 1.2 to about 5, from about 1.2 to about 4.8, from about 1.2 to about 4.5, from about 1.2 to about 4.2, from about 1.2 to about 3.8, from about 1.2 to about 3.6, from about 1.2 to about 3.4, about 1.2 to about 3.2, about 1.2 to about 3, about 1.4 to about 20, about 1.4 to about 15, about 1.4 to about 10, about 1.4 to about 5, about 1.4 to about 4.8, about 1.4 to about 4.5, about 1.4 to about 4.2, about 1.4 to about 4, about 1.4 to about 3.8, about 1.4 to about 3.5, about 1.4 to about 3.2, about 1.4 to about 3, about 1.6 to about 20, about 1.6 to 15, about 1. 6 to about 10, about 1.6 to about 5, about 1.6 to about 4.8, about 1.6 to about 4.5, about 1.6 to about 4, about 1.6 to about 3.8, about 1.6 to about 3.5, about 1.8 to about 20, about 1.8 to about 15, about 1.8 to about 10, about 1.8 to about 5, about 1.8 to about 4.8, about 1.8 to about 4.5, about 1.8 to about 4, about 1.8 to about 3.8, about 1.8 to about 3.5, about 2 to about 20, about 2 to about 15, about 2 to about 10, about 2 to about 5, about 2 to about 4.5, about 2 to about 4.2, about 2 to about 4, about 2 to about 3.8, about 2 to about 3.5, about 2.5 to about 20, about 2.5 to about 15, about 2.5 to about 10, about 2.5 to about 5, about 2.5 to about 4.8, about 2.5 to about 4.5, about 2.5 to about 4.2, about 2.5 to about 4, about 3 to about 20, about 3 to about 15, about 3 to about 10, about 3 to about 5, about 3 to about 4.8, about 3 to about 4.6, or about 3 to about 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 more uniformly dispersed in the dry electrode mixture or electrode slurry.

[0111] In conventional methods for preparing aqueous binder compositions, the resulting reaction mixture after polymerization is a wet binder composition. This wet binder composition is the final product and is used directly in electrode slurries. However, wet binder compositions contain a large amount of aqueous medium. In some cases, the liquid content of the wet binder composition can be 80% or more of the total weight of the wet binder composition. While such a high liquid content allows for excellent dispersion of the water-compatible copolymer, it also makes the storage and transportation of the binder composition very inefficient. Therefore, binder compositions with reduced liquid content are desirable.

[0112] Thus, in some embodiments, the post-reaction mixture is dried to remove the liquid and form a binder composition with reduced liquid content. In some embodiments, the dry binder composition is formed by drying the post-reaction mixture until substantially no liquid remains. In certain embodiments, the dry binder composition is formed by drying the post-reaction mixture until the liquid is completely removed.

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

[0114] The dryer used is not particularly limited, except that the dryer is capable of reducing the liquid content of the post-reaction mixture without decomposing the copolymer therein. 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 dry binder composition particles have a particle size D50 of about 10 μm to about 50 μm, about 12 μm to about 50 μm, about 14 μm to about 50 μm, about 16 μm to about 50 μm, about 18 μm to about 50 μm, about 20 μm to about 50 μm, about 20 μm to about 48 μm, about 20 μm to about 46 μm, about 20 μm to about 44 μm, about 20 μm to about 42 μm, about 20 μm to about 40 μm, about 22 μm to about 40 μm, about 22 μm to about 38 μm, about 24 μm to about 38 μm, about 24 μm to about 36 μm, about 26 μm to about 34 μm, about 28 μm to about 34 μm, or about 28 μm to about 32 μm.

[0116] In some embodiments, the particle size D50 of the dry 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 it is substantially free of liquid, maximum storage and transport efficiency can be achieved because the remaining liquid in the dry binder composition occupies negligible mass and volume. The dry binder composition can be used to make a dry electrode mix or electrode slurry, which can then be coated onto a current collector to form an electrode.

[0118] In other embodiments, the binder composition is a semi-dry binder composition. In some embodiments, the semi-dry binder composition is obtained by directly drying the post-reaction mixture to the desired solids content. In such cases, the semi-dry binder composition will have an aqueous solvent that is the same as or derived from the aqueous medium of the polymerization process. In other embodiments, to more precisely control the liquid content of the binder composition, the semi-dry binder composition is obtained by partially rehydrating the dry 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 an aqueous medium for a polymerization process is also suitable for rehydrating a 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 to a semi-dry binder composition, the dry binder composition is placed in a humid environment and allowed 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 to ensure that all of the binder composition can be rehydrated by the humid environment. There is no particular limitation on the stirring speed of the binder composition during rehydration, but the stirring speed should be fast enough to promote complete rehydration 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 limitations 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 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 1.5 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.

[0123] The period of time for which the dry binder composition is left in the humid environment is not particularly limited, other than that it should be long enough to allow the dry binder composition to absorb moisture from the humid environment and form a semi-dry binder composition. In some embodiments, the dry binder composition is left in the 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-dry binder composition is from about 1% to about 85% by weight, from about 1% to about 80% by weight, from about 1% to about 75% by weight, from about 1% to about 70% by weight, from about 1% to about 65% by weight, from about 1% to about 60% by weight, from about 1% to about 55% by weight, from about 1% to about 50% by weight, from about 1% to about 45% by weight, from about 1 to about 40% by weight, or from about 1 to about 35% by weight, based on the total weight of the semi-dry binder composition. , about 1 to about 30% by weight, about 1% to about 25% by weight, about 1% to about 20% by weight, about 10% to about 85% by weight, about 10% to about 80% by weight, about 10% to about 75% by weight, about 10% to about 70% by weight, about 10% to about 65% by weight, about 10% to about 60% by weight, about 10% to about 55% by weight, about 10% to about 50% by weight, about 10% to about 45% by weight, about 10% to about 40% by weight, about 10% to about 30% by weight 5% by weight, about 10% to about 30% by weight, about 10% to about 25% by weight, about 20% to about 85% by weight, about 20% to about 80% by weight, about 20% to about 75% by weight, about 20% to about 70% by weight, about 20% to about 65% by weight, about 20% to about 60% by weight, about 20% to about 55% by weight, about 20% to about 50% by weight, about 20% to about 45% by weight, about 20% to about 40% by weight, about 30% to 85% by weight, about 30% to about 80% by weight, about 30% to about 75% by weight, about 30% to about 70% by weight, about 30% to about 65% by weight, about 30% to about 60% by weight, about 30% to about 55% by weight, about 30% to about 50% by weight, about 40% to about 85% by weight, about 40% to about 80% by weight, about 40% to about 75% by weight, about 40% to about 70% by weight, about 40% to about 65% by weight, or about 40% to about 60% by weight.

[0125] In some embodiments, the liquid content of the semi-dry binder composition is about 1 wt%, about 2 wt%, about 3 wt%, about 4 wt%, about 5 wt%, about 6 wt%, about 7 wt%, about 8 wt%, about 9 wt%, about 10 wt%, about 11 wt%, about 12 wt%, about 13 wt%, about 14 wt%, about 15 wt%, about 16 wt%, about 17 wt%, or about 18 wt%, based on the total weight of the semi-dry 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 , about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, or about 85% by weight.

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

[0127] Although a low liquid content in a dry binder composition can help improve logistics efficiency, it is not always best to reduce the liquid content of the binder composition as much as possible. The aqueous solvent in a semi-dry binder composition can reduce the risk of powder explosion and the effects of static electricity. The semi-dry binder composition can be used to make an electrode slurry, which can be applied to a current collector to form an electrode.

[0128] In some embodiments, apart from the binder composition, the dry electrode mixture or electrode slurry includes an electrode active material. Such an electrode active material can be a positive electrode active material or a negative electrode active material. When the dry electrode mixture or electrode slurry includes a positive electrode active material, the dry electrode mixture or electrode slurry can 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 can 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 includes a conductive agent.

[0129] Many cathode 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. One method to waterproof such cathode active materials is to coat them to form core-shell cathode active materials. However, these methods increase manufacturing costs and time and may even adversely affect battery performance. Therefore, forming an electrode using a dry electrode mixture can prevent the degradation of the cathode active material due to reaction with water.

[0130] A dry electrode mix can be prepared using the dry binder composition disclosed herein, and no solvent is added in preparing the dry electrode mix. Thus, the dry electrode mix will include the electrode active material and the dry binder composition, and optionally, the conductive agent, but will be substantially free of liquid or free of liquid.

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

[0132] Conversely, the electrode slurry includes a liquid. The electrode slurry can be prepared using the dry or semi-dry binder composition disclosed herein. The liquid portion of the electrode slurry is comprised of an aqueous solvent, such as water, at least a portion of which can be derived from the aqueous solvent of the semi-dry binder composition.

[0133] Because the electrode slurry is liquid, it can be easily applied to a current collector to form an electrode 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 in the application process. Safety is also improved by reducing the risk of powder explosion.

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

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

[0136] As disclosed above, it is recognized that both dry electrode mixes and electrode slurries have their own advantages. Therefore, the binder compositions disclosed herein can be used as the binder composition for either a dry electrode mix or an electrode slurry, depending on production needs.

[0137] The method used to prepare the 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 prepare 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 optional conductive agent) is added to the homogenizer in several batches, and each batch can consist of multiple electrode components.

[0138] In some embodiments, when an additional solvent is added to the electrode slurry, the additional solvent is an aqueous solvent. Any aqueous solvent suitable as an aqueous medium for the polymerization process and / or as an aqueous solvent in the rehydration of a dry binder composition to a semi-dry binder composition is also suitable for use as an additional solvent in the electrode slurry. In some embodiments, when an additional solvent is added in the preparation of the electrode slurry, the additional solvent can be added before, after, and / or during 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 the dry electrode mix in a humid environment and absorbing water from the humid environment, which then acts as an additional solvent. When this method is used, the liquid content of the electrode slurry will be relatively low 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 at 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 wet environment is not particularly limited, but it is desirable for the specific humidity of the wet environment to be greater than the liquid content of the dry electrode mix to ensure that the dry electrode mix absorbs moisture from the wet environment to form an electrode slurry. In some embodiments, the specific humidity of the wet 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 period of time for which the dry electrode mix is ​​left in the humid environment is not particularly limited, except that it must be long enough to allow the dry electrode mix to absorb moisture from the humid environment and form an electrode slurry. In some embodiments, the dry electrode mix is ​​left in the humid environment for a period 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 The positive electrode active material is selected from the group consisting of LiNi x Co y Al z and combinations thereof, where each x is independently 0.1 to 0.9; each y is independently 0 to 0.9; and each z is independently 0 to 0.4. In some embodiments, each x, y, and z in the general formula above independently have an interval of 0.01. In other embodiments, the active cathode material is not LiCoO, LiNiO, LiV, LiTiS, LiMoS, LiMnO, LiCrO, LiMnO, LiFeO, or LiFePO. In further embodiments, the active cathode material is LiNi x Mn y O2, Li 1+z Ni x Mn y Co 1-x-y O2, LiNi 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 comprises a core-shell composite having a core and shell structure, or is a core-shell composite. In some embodiments, the core comprises one or more lithium transition metal oxides. In some embodiments, the shell comprises 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 band 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 of the lithium transition metal oxides 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, the 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 the core is composed of one or more lithium transition metal oxides. In some embodiments, the lithium transition metal oxides of the core and the shell may be the same, or they may be different or partially different. In some embodiments, when the core or shell is composed 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, when the core or shell is composed 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 each 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 within 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 core to 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 particulate, synthetic graphite particulate, hard carbon, soft carbon, mesocarbon microbeads (MCMB), Sn particulate, SnO, SnO, LiTiO 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 undoped. 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 comprises a core-shell composite having a core and a shell structure, or is a core-shell composite. In some embodiments, the core is made of natural graphite particles, synthetic graphite particles, hard carbon, soft carbon, mesocarbon microbeads (MCMB), Sn particles, SnO, SnO, or LiTiO. 12 In some embodiments, the shell is selected from the group consisting of soft carbon, hard carbon, natural graphite particles, synthetic graphite particles, mesocarbon microbeads (MCMB), kish graphite, pyrolytic carbon, mesophase pitch, mesophase pitch-based carbon fibers, Sn particles, SnO, SnO, LiTiO 12 The fine particles are selected from the group consisting 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 include a conductive agent. The conductive agent increases the electrical conductivity of the electrode. Therefore, it may be advantageous for the dry electrode mixture or electrode slurry to include a conductive agent. Any suitable material can act as the 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 fiber, carbon nanofiber, graphitized carbon flakes, carbon tubes, carbon nanotubes, activated carbon, Super P, KS6, steam-grown carbon fiber (VGCF), mesoporous carbon, and combinations thereof. In certain embodiments, the conductive agent does not include 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 include a conductive polymer.

[0153] The dry electrode mixture or electrode slurry may contain additives as needed to achieve 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 the binder copolymer in the solid portion of the dry electrode mix or electrode slurry is about 1 wt % to about 50 wt %, about 2 wt % to about 50 wt %, about 5 wt % to about 50 wt %, about 8 wt % to about 50 wt %, about 10 wt % to about 50 wt %, about 15 wt % to about 50 wt %, about 20 wt % to about 50 wt %, about 25 wt % to about 50 wt %, about 30 wt % to about 50 wt %, about 1 wt % to about 40 wt %, about 2 wt % to about 40 wt %, about 5 wt % to about 40 wt %, about 8 wt % to about 40 wt %, about 10 wt % to about 40 wt %, about 15 wt % to about 40 wt %, about 20 wt % to about 40 wt %, about 25 wt % to about 40 wt %, or about 30 wt % to about 40 wt %, based on the total weight of the solid portion of the dry electrode mix or electrode slurry, respectively. about 1% to about 30% by weight, about 2% to about 30% by weight, about 5% to about 30% by weight, about 8% to about 30% by weight, about 10% to about 30% by weight, about 15% to about 30% by weight, about 20% to about 30% by weight, 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.

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

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

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

[0158] In some embodiments, the percentage of electrode active material in the dry electrode mix or solid portion of the electrode slurry is 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, or about 65% to 95% by weight, based on the total weight of the dry electrode mix or solid portion of the electrode slurry, respectively. , about 70% to about 95% by weight, about 75% to about 95% by weight, about 80% to about 95% by weight, about 40% to about 90% by weight, about 45% to about 90% by weight, about 50% to about 90% by weight, about 55% to about 90% by weight, about 60% to about 90% by weight, about 65% to about 90% by weight, about 70% to about 90% by weight, about 75% to about 90% by weight, about 80% to about 90% by weight, about 40% to about 85% by weight, about 45% to about 85% by weight, about 50% to about 85% by weight, about 55% to about 85% by weight, about 60% to about 85% by weight, about 65% to about 85% by weight, about 70% to about 85% by weight, or about 75% to about 85% by weight.

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

[0160] In some embodiments, the percentage of additional solvent added to the electrode slurry is from about 0 wt % to about 60 wt %, from about 2 wt % to about 60 wt %, from about 5 wt % to about 60 wt %, from about 8 wt % to about 60 wt %, from about 10 wt % to about 60 wt %, from about 12 wt % to about 60 wt %, from about 15 wt % to about 60 wt %, from about 18 wt % to about 60 wt %, from about 20 wt % to about 60 wt %, from about 22 wt % to about 60 wt %, from about 25 wt % to about 60 wt %, from about 28 wt % to about 60 wt %, from about 30 wt % to about 60 wt %, from about 32 wt % to about 60 wt %, from about 40 wt % to about 60 wt %, from about 42 wt % to about 60 wt %, from about 46 wt % to about 60 wt %, from about 48 ... % to about 60% by weight, about 35% to about 60% by weight, about 38% to about 60% by weight, about 40% to about 60% by weight, about 42% to about 60% by weight, about 45% to about 60% by weight, about 0% 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 12% to about 50% by weight, about 15% to about 50% by weight, about 18% to about 50% by weight, about 20% to about 50% by weight, about 22% to about 50% by weight, about 25% to about 50% by weight 0% by weight, about 28% to about 50% by weight, about 30% to about 50% by weight, about 32% to about 50% by weight, about 35% to about 50% by weight, about 0% 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 12% to about 40% by weight, about 15% to about 40% by weight, about 18% to about 40% by weight, about 20% to 40% by weight, about 22% to 40% by weight, about 25% to 40% by weight, about 28% to 40% by weight, about 30% by weight to about 40% by weight, about 0% to about 30% by weight, about 2% to about 30% by weight, about 8% to about 30% by weight, about 10% to about 30% by weight, about 12% to about 30% by weight, about 15% to about 30% by weight, about 18% to about 30% by weight, about 20% to about 30% by weight, about 0% 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 0% to about 15% by weight, about 3% to about 15% by weight, or about 5% to about 15% by weight.

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

[0162] In some embodiments, the liquid content of the electrode slurry is from about 1 wt % to about 60 wt %, from about 3 wt % to about 60 wt %, from about 5 wt % to about 60 wt %, from about 8 wt % to about 60 wt %, from about 10 wt % to about 60 wt %, from about 12 wt % to about 60 wt %, from about 15 wt % to about 60 wt %, from about 18 wt % to about 60 wt %, from about 20 wt % to about 60 wt %, from about 23 wt % to about 60 wt %, from about 25 wt % to about 60 wt %, from about 28 wt % to about 60 wt %, from about 30 wt % to about 60 wt %, About 33% to about 60% by weight, about 35% to about 60% by weight, about 38% to about 60% by weight, about 40% to about 60% by weight, about 43% to about 60% by weight, about 45% to about 60% by weight, about 1% to about 50% by weight, about 3% 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 12% to about 50% by weight, about 15% to about 50% by weight, about 18% to about 50% by weight, about 20% to about 50% by weight, about 23% to about 50% by weight Amount %, about 25% to about 50% by weight, about 28% to about 50% by weight, about 30% to about 50% by weight, about 33% to about 50% by weight, about 35% to about 50% by weight, about 1% to about 40% by weight, about 3% to about 40% by weight, about 5% to about 40% by weight, about 8% to about 40% by weight, about 10% to 40% by weight, about 12% to 40% by weight, about 15% to 40% by weight, about 18% to 40% by weight, about 20% to 40% by weight, about 23% to 40% by weight, about 25% to 40% by weight, about 1% to about 30% by weight, about 3% to about 30% by weight, about 5% to about 30% by weight, about 8% to about 30% by weight, about 10% to about 30% by weight, about 12% to about 30% by weight, about 15% to about 30% by weight, about 1% to about 20% by weight, about 3% 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 1% to about 15% by weight, about 3% to about 15% by weight, about 5% to about 15% by weight, or about 1% to about 10% by weight.

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

[0164] The homogenizer may be equipped with a temperature control device, which may control the temperature of the dry electrode mixture or electrode slurry. Any homogenizer capable of reducing or eliminating particle agglomeration and / or promoting uniform distribution of the electrode components within the dry electrode mixture or electrode slurry may be used herein. Uniform distribution plays an important role in producing batteries with good electrochemical performance. In some embodiments, the homogenizer is a tumbler, mill, agitator mixer, 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 to produce a dry electrode mixture or electrode slurry is from about 1 minute to about 24 hours, from about 5 minutes to about 24 hours, from about 10 minutes to about 24 hours, from about 15 minutes to about 24 hours, from about 30 minutes to about 24 hours, from about 60 minutes to about 24 hours, from about 2 hours to about 24 hours, from about 4 hours to about 24 hours, from about 6 hours to about 24 hours, from about 2 hours to about 24 hours, from about 8 hours to about 24 hours, from about 10 hours to about 24 hours, from about 12 hours to about 24 hours, from about 16 hours to about 24 hours, from about 1 minute to about 16 hours, from about 5 minutes to about 16 hours, from about 10 minutes to about 16 hours, from about 15 minutes to about 16 hours, from about 30 minutes to about 16 hours, from about 60 minutes to about 16 hours, from about 2 hours to about 1 hour. 6 hours, about 4 hours to about 16 hours, about 6 hours to about 16 hours, about 8 hours to about 16 hours, about 10 hours to about 16 hours, about 12 hours to about 16 hours, about 1 minute to about 12 hours, about 5 minutes to about 12 hours, about 10 minutes to about 12 hours, about 15 minutes to about 12 hours, about 30 minutes to about 12 hours, about 60 minutes to about 12 hours, about 2 hours to about 12 hours, about 4 hours to about 12 hours, about 1 minute to about 6 hours, about 5 minutes to about 6 hours, about 10 minutes to about 6 hours, about 15 minutes to about 6 hours, about 30 minutes to about 6 hours, about 60 minutes to about 6 hours, about 2 hours to about 6 hours, about 1 minute to about 2 hours, about 5 minutes to about 2 hours, about 10 minutes to about 2 hours, about 15 minutes to about 2 hours, or about 30 minutes to about 2 hours.

[0166] In some embodiments, the total homogenization time to produce a dry electrode mix 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 to produce a dry electrode mix 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 heated to a temperature of from about 20°C to about 90°C, from about 25°C to about 90°C, from about 30°C to about 90°C, from about 35°C to about 90°C, from about 40°C to about 90°C, from about 50°C to about 90°C, from about 60°C to about 90°C, from about 70°C to about 90°C, from about 20°C to about 80°C, from about 25°C to about 80°C, from about 30°C to about 80°C, from about 35°C to about 80°C, The mixture is mixed at a temperature of about 40°C to about 80°C, about 50°C to about 80°C, about 60°C to about 80°C, about 20°C to about 70°C, about 25°C to about 70°C, about 30°C to about 70°C, about 35°C to about 70°C, about 40°C to about 70°C, about 50°C to about 70°C, about 20°C to about 60°C, about 25°C to about 60°C, 30°C to about 60°C, about 35°C to about 60°C, or about 40°C to about 60°C.

[0168] In some embodiments, the dry electrode mix 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 certain embodiments, the dry electrode mix 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 certain embodiments, the rotational speed of each rotating element within the homogenizer is independently from about 100 rpm to about 3000 rpm, from about 500 rpm to about 3000 rpm, from about 1000 rpm to about 3000 rpm, from about 1500 rpm to about 3000 rpm, from about 100 rpm to about 2500 rpm, from about 500 rpm to about 2500 rpm, from about 1000 rpm to about 2500 rpm, from about 1500 rpm to about 2500 rpm, from about 100 rpm to about 2000 rpm, from about 500 rpm to about 2000 rpm, from about 1000 rpm to about 2000 rpm, from about 100 rpm to about 1500 rpm, or from about 500 rpm to about 1500 rpm.

[0170] In certain embodiments, the rotational speed of each rotating element within 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 within 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 dry electrode mixture or electrode slurry can be used to manufacture an electrode. 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 coated onto 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 coated or calendered directly onto the current collector. In some embodiments, the dry electrode mixture or electrode slurry is coated or calendered onto a release film to form a free-standing layer. This free-standing layer is combined with a current collector and pressed to form a coated electrode film on the current collector.

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

[0174] The current collector functions to collect electrons generated by the electrochemical reaction of the positive electrode active material or to supply electrons required for the electrochemical reaction. In some embodiments, the current collector can be in the form of a foil, sheet, or film. In certain embodiments, the current collector is made of 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, where the outer layer is made of a conductive material and the inner layer is made of an insulating material or another conductive material; for example, aluminum attached with a conductive resin layer or a polymer insulating material coated 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, where the outer layer and the inner layer are made of a conductive material and the intermediate layer is made of an insulating material or another conductive material, for example, a plastic substrate coated with a metal film on both sides. In certain embodiments, the outer layer, the intermediate layer, and the inner layer are each independently made of stainless steel, titanium, nickel, aluminum, copper, or an alloy thereof, or a conductive resin. In some embodiments, the insulating material is a polymeric 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, polyphenyl oxide, cellulose polymers, and combinations thereof. In certain embodiments, the current collector has a structure consisting of three or more layers.

[0175] In certain embodiments, a conductive layer can be coated on 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 about 0.5 μm to about 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 thus the capacity of the battery.

[0177] In certain embodiments, the thickness of the conductive layer on the current collector is from about 0.5 μm to about 4.5 μm, from about 1.0 μm to about 4.0 μm, from about 1.0 μm to about 3.5 μm, from about 1.0 μm to about 3.0 μm, from about 1.0 μm to about 2.5 μm, from about 1.0 μm to about 2.0 μm, from about 1.1 μm to about 2.0 μm, from about 1.2 μm to about 2.0 μm, from about 1.5 μm to about 2.0 μm, from about 1.8 μm to about 2.0 μm, from about 1.0 μm to about 1.8 μm, from about 1.2 μm to about 1.8 μm, from about 1.5 μm to about 1.8 μm, from about 1.0 μm to about 1.5 μm, or about 1.2 μm. 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 in the battery and, therefore, the energy density of the battery. In some embodiments, the current collector has a thickness of about 5 μm to about 30 μm. In specific embodiments, the current collector has a thickness of about 5 μm to about 20 μm, about 5 μm to about 15 μm, about 10 μm to about 30 μm, about 10 μm to about 25 μm, or about 10 μm to about 20 μm.

[0179] In some embodiments, after a dry electrode mixture or electrode slurry is applied to a current collector to form a coating, the coating is heated and / or dried. Any device capable of heating and / or drying a coating to attach a coating layer to a current collector can be used herein. Some non-limiting examples of devices that can be used to heat and / or dry a coating include a batch drying oven, a conveyor drying oven, and a microwave drying oven. Some non-limiting examples of conveyor drying ovens include a conveyor hot air drying oven, a conveyor resistance drying oven, a conveyor induction drying oven, and a conveyor microwave drying oven. When a coating is produced 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 adhesion to the current collector. Even when a coating is produced using a dry electrode mixture, drying may be performed to further reduce the liquid content of the coating.

[0180] The conditions for heating and / or drying the coated film are not particularly limited, but it is desirable that the coated 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 deteriorate from the heat and so that the risk of significant temperature gradients due to uneven heating, which could cause deformation or peeling of the electrode, is reduced.

[0181] In some embodiments, the coating on the current collector can be heated to a temperature of from about 50°C to about 160°C, from about 60°C to about 160°C, from about 70°C to about 160°C, from about 80°C to about 160°C, from about 90°C to about 160°C, from about 95°C to about 160°C, from about 100°C to about 160°C, from about 105°C to about 160°C, from about 110°C to about 160°C, from about 115°C to about 160°C, from about 120°C to about 160°C, about 125°C to about 160°C, about 130°C to about 160°C, about 140°C to about 160°C, about 60°C to about 150°C, about 70°C to about 150°C, about 80°C to about 150°C, about 90°C to about 150°C, about 95°C to about 150°C, about 100°C to about 150°C, about 105°C to about 150°C, about 110°C to about 150°C, about 115°C to about 150°C, about 120°C to about 150°C, about 60°C to about 140°C, about 70°C to about 140°C, about 80°C to about 140°C, about 90°C to about 140°C, about 95°C to about 140°C, about 100°C to about 140°C, about 105°C to about 140°C, about 110°C to about 140°C, about 115°C to about 140°C, about 120°C to about 140°C, about 60°C to about 130°C, about 70°C to about 130°C, about 80°C to about 130°C, about 90°C to about 130°C, about 97°C to about 130°C, about 100°C to about 130°C. The composition may be heated and / or dried at a temperature of from about 105°C to about 130°C, from about 110°C to about 130°C, from about 60°C to about 120°C, from about 70°C to about 120°C, from about 80°C to about 120°C, from about 90°C to about 120°C, from about 95°C to about 120°C, from about 100°C to about 120°C, from 60°C to about 110°C, from about 70°C to about 110°C, from about 80°C to about 110°C, from about 90°C to about 110°C, from about 60°C to about 100°C, from about 70°C to about 100°C, or from about 80°C to about 100°C.

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

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

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

[0185] In certain embodiments, the thickness of the electrode layer is from about 5 μm to about 90 μm, from about 5 μm to about 50 μm, from about 5 μm to about 25 μm, from about 10 μm to about 90 μm, from about 10 μm to about 50 μm, from about 10 μm to about 30 μm, from about 15 μm to about 90 μm, from about 20 μm to about 90 μm, from about 25 μm to about 90 μm, from about 25 μm to about 80 μm, from about 25 μm to about 70 μm, from about 25 μm to about 50 μm, from about 30 μm to about 90 μm, or from about 30 μm to about 80 μm. In some embodiments, the thickness of the electrode layer 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, hi some embodiments, the thickness of the electrode layer 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 about 1 mg / cm 2 to approximately 5 mg / cm 2 , about 3mg / cm 2 to approximately 50 mg / cm 2 , about 5mg / cm 2 to approximately 50 mg / cm 2 , about 10mg / cm 2 to approximately 50 mg / cm 2 , about 1mg / cm 2 to approximately 50 mg / cm 2 , about 20mg / cm 2 to approximately 50 mg / cm 2 , about 30mg / cm 2 to approximately 50 mg / cm 2 , about 1mg / cm 2 to approximately 30 mg / cm 2 , about 3mg / cm 2 to approximately 30 mg / cm 2 , about 5mg / cm 2 to approximately 30 mg / cm 2 , about 10mg / cm 2 to approximately 30 mg / cm 2, about 15mg / cm 2 to approximately 30 mg / cm 2 , about 20mg / cm 2 to approximately 30 mg / cm 2 , about 1mg / cm 2 to approximately 20 mg / cm 2 , about 3mg / cm 2 to 20 mg / cm 2 , about 5mg / cm 2 to approximately 20 mg / cm 2 , about 10mg / cm 2 to approximately 20 mg / cm 2 , about 1mg / cm 2 to approximately 15 mg / cm 2 , about 3mg / cm 2 to approximately 15 mg / cm 2 , about 5mg / cm 2 to approximately 15 mg / cm 2 , or approximately 10 mg / cm 2 to approximately 15 mg / cm 2 is.

[0187] In some embodiments, the surface density of the electrode layer is 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 Less than or equal to 3 mg / cm 2 In some embodiments, the surface density of the electrode layer is less 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 greater than or 40 mg / cm 2 Greater than.

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

[0189] Furthermore, electrodes fabricated using the dry electrode mixture or electrode slurry prepared using the binder composition of the present invention exhibit strong adhesion of the electrode layer to the current collector. Having good peel strength between the electrode layer and the current collector is important for preventing electrode peeling or separation, which significantly affects the mechanical stability of the electrode and the cycleability of the battery. Therefore, it is desirable for the electrode to have 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 from about 1.0 N / cm to about 8.0 N / cm, from about 1.0 N / cm to about 6.0 N / cm, from about 1.0 N / cm to about 5.0 N / cm, from about 1.0 N / cm to about 4.0 N / cm, from about 1.0 N / cm to about 3.0 N / cm, from about 1.0 N / cm to about 2.5 N / cm, from about 1.0 N / cm to about 2.0 N / cm, from about 1.2 N / cm to about 3.0 N / cm, from about 1.2 N / cm to about 2.5 N / cm, from about 1.2 N / cm to 2.0 N / cm, from about 1.5 N / cm to about 3.0 N / cm, from about 1.5 N / cm to about 2.5 N / cm, from about 1.5 N / cm to about 2.0 N / cm, from about 1.8 N / cm to about 3.0 N / cm, or from about 1.8 N / cm to about 2.5 N / cm. N / cm to about 2.5 N / cm, about 2.0 N / cm to about 6.0 N / cm, about 2.0 N / cm to about 5.0 N / cm, about 2.0 N / cm to about 3.0 N / cm, about 2.0 N / cm to about 2.5 N / cm, about 2.2 N / cm to about 3.0 N / cm, about 2.5 N / cm to about 3.0 N / cm, about 3.0 N / cm to about 8.0 N / cm, about 3.0 N / cm to about 6.0 N / cm, or about 4.0 N / cm to about 6.0 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] FIG. 1 is a flowchart illustrating a simplified summary of several embodiments of various aspects of the invention disclosed herein. As shown, following polymerization, the post-reaction mixture is dried to a substantially water-free state. 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 the binder composition. To form a dry electrode mixture from the 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 the dry binder composition, the dry binder composition is mixed with an electrode active material and additional solvent, and, optionally, a conductive agent. To form a semi-dry electrode slurry from the semi-dry binder composition, the semi-dry binder composition is mixed with an electrode active material and, optionally, a conductive agent and / or additional solvent.

[0193] The binder compositions disclosed herein have several advantages. Most importantly, the low liquid content of the binder compositions disclosed herein, compared to conventional wet binder compositions, ensures greater efficiency in storage and transportation of the binder compositions, thereby helping to streamline the electrode manufacturing supply chain. It has been found that the dry binder compositions disclosed herein can be used directly in dry electrode mixes, as well as in electrode slurries after being rehydrated to semi-dry binder compositions. In both cases, batteries containing electrodes fabricated using the dry or semi-dry binder compositions disclosed herein were found to have similar mechanical and electrochemical performance compared to batteries containing electrodes fabricated 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 binder compositions disclosed herein are effective in both the dry and rehydrated states, thereby demonstrating the versatility of the copolymers.

[0194] The following examples are presented to illustrate embodiments of the present invention, but are not intended to limit the invention to the specific embodiments set forth. Unless otherwise indicated, all parts and percentages are by weight. All numerical values ​​are approximate. When numerical ranges are given, it should be understood that embodiments outside the stated ranges may still fall within the scope of the invention. The specific details disclosed in each example should not be construed as necessary features of the invention.

[0195] Example The peel strength of the electrode layer was measured using a tensile tester (DZ-106A, obtained from Dongguan Zonhow Test Equipment Co. Ltd., China). This test measures the average force, in Newtons, required to peel the electrode layer from the current collector at an angle of 180°. The current collector had a mean roughness depth (Rz) of 2 μm. A strip of adhesive tape (3M, USA, Model No. 810) measuring 18 mm wide and 20 mm long was attached to the surface of the electrode layer. The electrode piece was clamped in the tester, and the tape was folded back 180°, then placed in the movable jaw and pulled at room temperature at a peel rate of 200 mm / min. The maximum peel force measured was taken 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 5 hours or more. 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 between 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" x 100% Here, x may refer to the binder composition, the dry electrode mix, or the electrode slurry.

[0197] The weight-average and number-average molecular weights 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 gently filtered through a 0.45 μm filter to prepare the measurement sample. A calibration curve was created using polystyrene standards to calculate the weight-average and number-average molecular weights of the copolymer. The resulting measurement sample was analyzed using an Agilent PLgel 5 μm MIXED-C column. The flow rate was 1 mL / min, and the sample weight was 2 mg. The detector used was a Waters 2414 Refractive Index (RI) detector, with a detection temperature of 35°C.

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

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

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

[0201] 12.73 g of acrylonitrile was added to the third suspension, and the mixture was stirred for an additional 10 minutes at 80 rpm to obtain a fourth suspension.

[0202] Additionally, 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 Canna Chemical Reagent Factory, China) was dissolved in 1.5 g of DI water. The entire 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 a fifth suspension.

[0203] After the reaction was completed, 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 a sixth suspension. The sixth suspension was filtered using a 200 μm nylon mesh. The solids content of the filtered sixth suspension was 9.00 wt%.

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

[0205] B) Preparation of the positive electrode First, 0.9 g of conductive agent (KS6: obtained from ANR Technologies Pte. Ltd., Singapore), 0.90 g of binder composition, and 28.2 g of NMC532 (obtained from Shandong Tianjiao New Energy Co. Ltd., China) were milled to form a homogeneous mixture. 20.0 g of DI water was then added, and further milling was performed to form a homogenized positive electrode slurry. The solids 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 as a current collector. The coating film on the aluminum foil was dried at approximately 80°C for 120 minutes using a hot air dryer (DHG10H, Huyue Equipment Co., Ltd., China) to form a positive electrode layer. The electrode was then pressed to a thickness of 34 μm and an areal density of 5 mg / cm. 2 was reduced to.

[0207] C) Coin Cell Battery Assembly CR2032 coin-type Li batteries were assembled in an argon-filled glove box. The positive electrode sheet was cut into disc-shaped positive electrodes. A 500 μm-thick lithium metal foil was used as 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 at 105 °C for approximately 16 hours in a vacuum box resistance oven (DZF-6020, obtained from Shenzhen Kejing Star Technology Co. Ltd., China). After drying, the moisture contents of the separator and electrode assembly were 200 ppm and 300 ppm, respectively.

[0208] Next, the case holding the filled electrodes was filled with electrolyte under a high-purity argon atmosphere with moisture and oxygen levels below 3 ppm. 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 battery was mechanically pressed using a standard circular punch die.

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

[0210] Example 2 A positive electrode was fabricated in the same manner as in Example 1, except that the binder compositions were prepared by adding 7.45 g of sodium hydroxide to the first suspension, 16.77 g of acrylic acid to the second suspension, 7.19 g of acrylamide to the third suspension, and 35.55 g of acrylonitrile to the fourth suspension. The filtered sixth suspension had a solids concentration of 8.88 wt %. The binder composition had a weight-average molecular weight of 160,900 g / mol, a number-average molecular weight of 71,000 g / mol, and a polydispersity index of 2.27.

[0211] Example 3 A positive electrode was fabricated in the same manner as in Example 1, except that 30.10 g of sodium hydroxide was added to the first suspension, 56.92 g of acrylic acid was added to the second suspension, 7.19 g of acrylamide was added to the third suspension, and 5.90 g of acrylonitrile was added to the fourth suspension when preparing the binder composition. The solids content of the filtered sixth suspension was 9.82 wt %.

[0212] Example 4 A positive electrode was fabricated in the same manner as in Example 1, except that, when preparing the binder composition, 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 solids content of the filtered sixth suspension was 8.64 wt %.

[0213] Example 5 A positive electrode was fabricated in the same manner as in Example 1, except that, when preparing the binder compositions, 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 solids content of the filtered sixth suspension was 8.38 wt %.

[0214] Example 6 A positive electrode was fabricated in the same manner as in Example 1, except that, when preparing the binder compositions, 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 solids content of the filtered sixth suspension was 7.22 wt %.

[0215] Example 7 A) Preparation of the 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 DI water to dry powder mass ratio of 1:2. This binder composition was a semi-dry binder composition with a liquid content of 33.3 wt %.

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

[0217] Example 8 A) Preparation of the 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 1:1 mass ratio of DI water to dry powder. This binder composition was a semi-dry binder composition with a liquid content of 50 wt %.

[0218] B) Preparation of the positive electrode A positive electrode was fabricated in the same manner as in Example 1, except that 1.80 g of the binder composition (liquid content 50 wt %) and 19.10 g of DI water were added in preparing the homogeneous positive electrode slurry.

[0219] Example 9 A) Preparation of the 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 DI water to dry powder mass ratio of 2:1. This binder composition was a semi-dry binder composition with a liquid content of 66.7 wt.%.

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

[0221] Example 10 A) Preparation of the 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 then 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] Preparation of the positive electrode A positive electrode was fabricated in the same manner as in Example 1, except that in preparing the homogeneous positive electrode slurry, 4.50 g of the binder composition (liquid content: 80 wt %) and 17.30 g of DI water were added.

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

[0224] B) Preparation 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 ground using a mill to form a homogenized dry cathode mixture.

[0225] 0.2 g of this homogenized positive electrode mixture was hot-pressed onto one side of a 16 μm thick aluminum foil as a current collector, and the coating on the aluminum foil was vacuum-dried at approximately 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 prepared 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 prepared in the same manner as in Example 1, except that NMC532 was replaced with the same weight of LFP (Tianjin Sitelan Energy Technology Co. Ltd., China).

[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 The coin cells of Examples 2-13 were analyzed in the same manner as in Example 1. The electrochemical performance of the coin cells of Examples 2-13 was measured and is shown in Table 1 below.

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

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

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

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

[0235] Comparative Example 4 A positive electrode was fabricated in the same manner as in Example 1, except that, when preparing the binder compositions, 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, no acrylamide was added in the preparation of the third suspension, and 18.57 g of acrylonitrile was added in the preparation of the fourth suspension. The solids content of the filtered sixth suspension was 9.63 wt %.

[0236] Comparative Example 5 A positive electrode was fabricated in the same manner as in Example 1, except that, when preparing the binder composition, 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 no acrylonitrile was added in the preparation of the fourth suspension. The solids content of the filtered sixth suspension was 9.92 wt %.

[0237] Comparative Example 6 A positive electrode was fabricated in the same manner as in Example 1, except that, when preparing the binder compositions, 1.86 g of sodium hydroxide was added in the preparation of the first suspension, no 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, 37.14 g of acrylonitrile was added in the preparation of the fourth suspension, and no sodium hydroxide was added in the preparation of the sixth suspension. The solids content of the filtered sixth suspension was 7.15 wt %.

[0238] Comparative Example 7 A) Preparation of the 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 then 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-dry binder composition with a liquid content of 66.7 wt%.

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

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

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

[0242] Comparative Example 10 A positive electrode was prepared in the same manner as in Example 11, except that 0.9 g of dry 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 In the same manner as in Example 1, a coin battery of Comparative Example 1-13 was assembled.

[0247] Electrochemical measurements of Comparative Examples 1-13 The 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 is 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 specific features of one embodiment should not be attributed to other embodiments of the invention. In some embodiments, the method may include numerous steps not mentioned herein. In other embodiments, the method does not include, or is substantially free of, any steps not listed herein. Variations and modifications from the described embodiments exist. The appended claims are intended to cover all such modifications and variations as fall within the scope of the present invention. The inventions described in the original claims of the present application are set forth below. [1] A binder composition comprising a water-compatible copolymer, the binder composition having a liquid content of less than 85 wt. % based on the total weight of the binder composition. [2] The binder composition of [1], wherein the binder composition has a liquid content of less than 50 wt % or less than 25 wt % based on the total weight of the binder composition. [3] The binder composition of [1], wherein the binder composition has a liquid content of less than 1 wt % based on the total weight of the binder composition. [4] 1. The binder composition of claim 1, wherein the water-compatible copolymer comprises structural units (a) derived from acid group-containing monomers, wherein the acid groups are selected from carboxylic acid, sulfonic acid, sulfuric acid, phosphonic acid, phosphoric acid, nitric acid, salts of these acids, derivatives of these acids, and combinations thereof, and the proportion of structural units (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 of [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 from about 5 mol % to about 90 mol % based on the total number of moles of monomer units in the copolymer. [6] The binder composition of [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 of [1], wherein the liquid content is derived from an aqueous solvent. [8] The binder composition according to [7], wherein the aqueous solvent is water. [9] The binder composition of [1], wherein the weight average molecular weight of the water-compatible copolymer in the binder composition is from about 10,000 g / mol to about 1,000,000 g / mol.

[10] The binder composition of [1], wherein the number average molecular weight of the water-compatible copolymer in the binder composition is from about 10,000 g / mol to about 500,000 g / mol.

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

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

[13] The electrode slurry according to

[12] , further comprising a conductive agent.

[14] The electrode slurry of

[12] , wherein the liquid content of the electrode slurry is derived from an aqueous solvent.

[15] The electrode slurry according to

[14] , wherein the aqueous solvent is water.

[16] The electrode slurry according to

[12] , wherein the proportion of the electrode active material in the solid portion of the electrode slurry is about 40 wt % to about 99 wt % based on the total weight of the solid portion of the electrode slurry.

[17] A dry electrode mixture comprising the binder composition of [3] and an electrode active material.

[18] The dry electrode mixture according to

[17] , further comprising a conductive agent.

[19] The dry electrode mixture of

[17] , wherein the proportion of the electrode active material in the dry electrode mixture is about 40 wt % to about 99 wt % based on the total weight of the dry electrode mixture.

[20] The dry electrode mix of

[17] has a liquid content of less than 1 wt. % based on the total weight of the dry electrode mix.

Claims

1. A binder composition comprising a water-compatible copolymer, the binder composition having a liquid content of less than 85 wt. % based on the total weight of the binder composition; The water compatible copolymer comprises structural units (a) derived from acid group-containing monomers, the acid groups being selected from the group consisting of carboxylic acid, sulfonic acid, sulfuric acid, phosphonic acid, phosphoric acid, nitric acid, salts of these acids, derivatives of these acids, and combinations thereof, and the proportion of structural units (a) in the water compatible copolymer is from 5 mol % to 95 mol %, based on the total number of moles of monomer units in the water compatible copolymer; The water-compatible copolymer further comprises structural units (b) derived from amide group-containing monomers, and the proportion of structural units (b) in the water-compatible copolymer is 5 mol % to 90 mol % based on the total number of moles of monomer units in the water-compatible copolymer; 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, and combinations thereof, and the proportion of structural units (c) in the water-compatible copolymer is 10 mol % to 95 mol % based on the total number of moles of monomer units in the water-compatible copolymer; and The binder composition wherein the water-compatible copolymer does not contain structural units derived from a fluorine-containing monomer.

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

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

4. A binder composition as described in claim 1, wherein the proportion of structural unit (a) in the water-compatible copolymer is 10 mol% to 80 mol% based on the total number of moles of monomer units in the water-compatible copolymer.

5. A binder composition as described in claim 1, wherein the proportion of structural unit (b) in the water-compatible copolymer is 10 mol% to 35 mol% based on the total number of moles of monomer units in the water-compatible copolymer.

6. A binder composition described in claim 1 or 5, wherein the proportion of structural unit (c) in the water-compatible copolymer is 10 mol% to 80 mol% based on the total number of moles of monomer units in the water-compatible copolymer.

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

8. 8. The binder composition of claim 7, wherein the aqueous solvent comprises water.

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

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

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

12. The binder composition of claim 1, wherein the binder composition is used in a lithium ion battery.

13. 10. An electrode slurry comprising the binder composition of claim 1 and an electrode active material, wherein the electrode slurry has a liquid content of 1 wt % to 60 wt % based on the total weight of the electrode slurry.

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

15. 14. The electrode slurry of claim 13, wherein the liquid content of the electrode slurry is derived from an aqueous solvent.

16. 16. The electrode slurry of claim 15, wherein the aqueous solvent comprises water.

17. 14. The electrode slurry according to claim 13, wherein a proportion of the electrode active material in the solid portion of the electrode slurry is 40% by weight to 99% by weight based on the total weight of the solid portion of the electrode slurry.

18. The electrode active material includes LiCoO 2 , LiNiO 2 , LiNix Mny O 2 , LiCo x Ni y O 2 , Li 1+z Ni x Mny Co 1-x-y O 2 , LiNix Co y Al z O 2 , LiV 2 O 5 , LiTiS 2 , LiMoS 2 , LiMnO 2 , LiCrO 2 , LiMn 2 O 4 , Li 2 MnO 3 , LiFeO 2 , Li 1+d Ni a Mn b Co c Al (1-a-b-c) O 2 , LiM 1 PO 4 , LiNi e Mn f O 4 , gLi 2 MnO 3 ·(1-g)LiM 2 O 2 , Li 3 V 2 (PO 4 ) 3 , LiVPO 4 F, Li 2 M 3 SiO 4 , and mixtures thereof, wherein each x is independently 0.1 to 0.9, each y is independently 0 to 0.9, and each z is independently 0 to 0.4; -0.2≦d≦0.2, 0≦a<1, 0≦b<1, 0≦c<1, and a+b+c≦1, M 1 is Fe, Co, Ni, Mn, Al, Mg, Zn, Ti, La, Ce, Sn, Zr, Ru, Si, 14. The electrode slurry of claim 13, wherein M2 is selected from the group consisting of Ni, Co, Mn and combinations thereof, and M3 is selected from the group consisting of Fe, Co, Mn, Ni and combinations thereof.

19. A dry electrode mix comprising the binder composition of claim 1 and an electrode active material.

20. 20. The dry electrode mix of claim 19, wherein the dry electrode mix further comprises a conductive agent.

21. 20. The dry electrode mix of claim 19, wherein the percentage of electrode active material in the dry electrode mix is ​​40% to 99% by weight based on the total weight of the dry electrode mix.

22. 20. The dry electrode mix of claim 19, wherein the dry electrode mix has a liquid content of less than 1 wt. % based on the total weight of the dry electrode mix.

23. The electrode active material includes LiCoO 2 , LiNiO 2 , LiNix Mny O 2 , LiCo x Ni y O 2 , Li 1+z Ni x Mny Co 1-x-y O 2 , LiNix Co y Al z O 2 , LiV 2 O 5 , LiTiS 2 , LiMoS 2 , LiMnO 2 , LiCrO 2 , LiMn 2 O 4 , Li 2 MnO 3 , LiFeO 2 , Li 1+d Ni a Mn b Co c Al (1-a-b-c) O 2 , LiM 1 PO 4 , LiNi e Mn f O 4 , gLi 2 MnO 3 ·(1-g)LiM 2 O 2 , Li 3 V 2 (PO 4 ) 3 , LiVPO 4 F, Li 2 M 3 SiO 4 , and mixtures thereof, wherein each x is independently 0.1 to 0.9, each y is independently 0 to 0.9, and each z is independently 0 to 0.4; -0.2≦d≦0.2, 0≦a<1, 0≦b<1, 0≦c<1, and a+b+c≦1, M 1 is Fe, Co, Ni, Mn, Al, Mg, Zn, Ti, La, Ce, Sn, Zr, Ru, Si, 20. The dry electrode mix of claim 19, wherein M2 is selected from the group consisting of Ni, Co, Mn and combinations thereof, and M3 is selected from the group consisting of Fe, Co, Mn, Ni and combinations thereof.

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