Electrodes for energy storage devices

Abstract

Electrochemical energy storage device electrodes formed from electrostatic deposition processes use composite particles that include an attached binder and optionally conductive particles along with active material (AM) particles formed by interaction forces between the individual component particles sufficient to form an effective composite particle capable of overcoming particle separation during electrostatic charging, fluidization, and / or mechanical transport. The secondary binder particles undergo deagglomeration to form subparticles attached to the AM particles with a predetermined morphology. Smaller conductive particles, typically carbon black (CB) or similar carbon, bind to the binder and adhere to the AM particles. The result is a composite particle that is attached to withstand the separation forces imposed on the current collector by electrostatic deposition. Applying multiple composite particles in a uniform pattern and at a defined loading onto the conductive current collector promotes robust energy density, power density, and cycle life for the electrochemical energy storage device.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. provisional patent application entitled "Electrode for Energy Storage Device," filed on January 31, 2022 and assigned Serial No. 63 / 304,907, and to U.S. non-provisional patent application entitled "Electrode for Energy Storage Device," filed on April 5, 2022 and assigned Serial No. 17 / 713,722. The entire contents of the foregoing provisional and non-provisional applications are incorporated herein by reference.

[0002] 1.Technical Field The present disclosure is directed to electrochemical energy devices and related methods of manufacturing. The disclosed electrochemical energy devices generally include an electrode, where the electrode comprises, at least in part, a coating layer formed by depositing dry composite particles onto a conductive substrate by an electrostatic deposition process. The composite particles include active material particles and binder particles surrounding the active material particles, where the binder particles are generally formed from deagglomeration of binder agglomerates and adhere to the surfaces of the active material particles through particle-to-particle adhesion forces. [Background technology]

[0003] 2.Background technology Electrochemical energy storage devices have electrodes containing coating layers in communication with conductive current collector layers, typically copper or aluminum sheets. The coating layers may include cathode and anode active materials, and are often combined with conductive and binder materials to form a structure that readily discharges and accepts charge (is charged) in response to an applied electrical load or charging potential. The formation of the electrochemically active materials, binders, and conductive particles can vary depending on the applicable battery chemistry and production method.

[0004] Conventional approaches to battery manufacturing use a solvent-based approach to form electrodes, which typically involve a binder solution or suspension to flow or apply electrochemically active material and conductive particles onto a conductive current collector foil. Conventional methods generally involve solvents that pose handling, ventilation, and safety issues, and require drying times for the liquid solvent to evaporate or to fuse the components within the coated layer. Summary of the Invention [Problem to be solved by the invention]

[0005] Generally, to produce batteries with optimal energy density, power density, and cycle life, it is desirable to form a coating layer in which the electrochemically active material, conductive particles, and binder are uniformly dispersed at a density that promotes electrical communication between the electrochemically active material and the current collector. Improvements are desired in methods of applying the coating layer and in the electrochemically active material formed thereby. These and other objectives are met by the methods and apparatus of the present disclosure. [Means for solving the problem]

[0006] Provided are electrodes for electrochemical energy storage devices formed from an electrostatic deposition process using composite particles comprising electrochemically active material (or active material "AM") particles and attached binder particles, and optionally conductive particles, formed by sufficient interaction between the individual component particles to form effective composite particles capable of overcoming / resisting forces that separate the particles during electrostatic charging and fluidization in the electrostatic deposition process.

[0007] Commercially available binder or conductive materials are generally available in the form of agglomerates formed by the physical interaction of multiple primary particles, often referred to as secondary particles. According to the present disclosure, binder agglomerates undergo deagglomeration to form subparticles and attach to AM particles having a predetermined and / or desired morphology. It is noted that conductive aggregates also form subparticles through deagglomeration. Subparticles include one or more primary particles having a smaller size than the original agglomerates. In forming the advantageous energy storage devices of the present disclosure, binder particles and conductive particles are incorporated in the form of subparticles.

[0008] Typically, according to the present disclosure, carbon black (CB) or similar carbon is bound to a binder and adheres to the AM particles along with the binder. The result is a composite particle that exhibits sufficient adhesion to withstand the separation forces imposed during the electrostatic deposition process. In a typical electrostatic spray deposition (ESD) process, the composite particles disclosed herein are aerated and fluidized by a gas flow, carried by the gas flow, and deposited in a uniform pattern and density onto a conductive current collector. Alternative electrostatic deposition approaches may also be used.

[0009] The composite particle layer deposited on the current collector may be further densified according to the present disclosure to form a battery electrode. The uniformity of the deposited composite particle layer is critical to the performance of the resulting battery. Uniformity of the deposited composite particle layer involves, among other things, stoichiometric matching between the deposited layer and the feedstock powder mixture, as well as stoichiometric matching and shape matching within the deposited layer.

[0010] There is considerable commercial interest in the battery industry in applying electrostatic deposition techniques to form solvent-free electrode coatings for Li-ion batteries. Solvent-free electrode coating techniques are particularly attractive because ESD technology can significantly reduce the energy consumption in the manufacturing process, thereby significantly lowering the manufacturing costs of batteries. In principle, the use of electrostatic deposition techniques allows for simpler and more versatile electrode coatings in the manufacture of energy storage devices, since composite electrode powders are deposited directly onto metal current collectors through the electrostatic spray deposition process.

[0011] In conventional applications, electrostatic deposition techniques are widely used in dry powder coating of conductive components. In conventional applications of electrostatic deposition coating techniques, the quality of the coating layer, particularly the uniformity of the coating layer, is directly related to and dependent on the properties of the particles contained in the coating powder. These properties include particle size, dielectric constant, conductivity, density, and morphology. According to the present disclosure, the particle properties associated with the coating powder are selected such that electrostatically deposited coatings formed with the disclosed composite particles advantageously promote / provide uniform electrodes for battery applications.

[0012] The configurations herein can advantageously meet the need for reliable batteries across a range of end-use applications, particularly electric vehicles (EVs), which are subject to significant current draws to provide adequate vehicle performance. Unfortunately, as noted above, conventional approaches to battery manufacturing use solvent-based approaches to form electrodes, which typically involve a binder solution or suspension to flow or apply electrochemically active materials and conductive particles onto a conductive current collector foil. Conventional methods involve solvents that pose handling, ventilation, and safety issues, and require drying times for the liquid solvent to evaporate or to fuse the components within the coated layer. Thus, the configurations herein substantially overcome the above-mentioned shortcomings of solvent-based battery formulations by using an electrostatic deposition approach to provide electrodes comprising composite particles on a conductive current collector for dry powder applications.

[0013] As disclosed herein, the desired morphology or structure of the composite particles results from deagglomeration, mixing, and adhesion between the component particles to form active material (AM) particles with attached binder and optional conductive particles in a form that withstands electrostatic deposition processing. When deposited onto a conductive current collector substrate, the disclosed AM particles form / define the correct loading and microstructure for high performance batteries. It should be noted that "loading" is the unit coating layer mass over a specific area, typically in mg / cm. 2 It is a unit.

[0014] As disclosed herein, advantageous electrodes are formed on conductive current collectors by electrostatic deposition of composite particles, thereby forming highly effective electrodes / electrochemical energy storage devices. The disclosed electrodes / electrochemical energy storage devices generally comprise a plurality of composite particles adapted for electrostatic deposition on a conductive current collector substrate, each composite particle comprising one or more active material particles, binder particles surrounding the active material particles, and conductive particles attached to the binder particles. The disclosed binder particles are generally formed through deagglomeration of binder agglomerates to form subparticles. The binder particles adhere to the surfaces of the active material particles through interaction forces sufficient to withstand the powder mixing process. The interaction is also sufficient to overcome the separation forces caused by the electrostatic deposition process, which is ideal for maintaining the structure of the composite particles when formed on a conductive current collector substrate by the electrostatic deposition process. [Effects of the Invention]

[0015] The disclosed electrochemical energy storage devices and methods for their production are highly advantageous in providing effective energy storage capabilities without the need for solvent-based manufacturing methods.

[0016] Additional features, functions, and benefits of the disclosed electrochemical energy storage devices and related methods of manufacture will become apparent from the detailed description that follows, particularly when read in conjunction with the accompanying drawings.

[0017] The foregoing and other features will become apparent from the following description of specific embodiments set forth herein, as illustrated in the accompanying drawings, in which like reference characters refer to the same parts throughout the various views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a diagram of a composite particle, where composite particle 101C represents a composite particle disclosed herein. [Figure 2] FIG. 2 shows a context / example system for deploying the composite particle of FIG. 1 (composite particle 101C) in an electrochemical energy storage device. [Figure 3A] FIG. 2 shows an example composition of the composite particle of FIG. 1. [Figure 3B] FIG. 2 shows an example composition of the composite particle of FIG. 1. [Figure 4] FIG. 3C illustrates the progression through the formation of the composite particle of FIGS. 1-3B. [Figure 5A] 1 is an SEM image of the mixed powder for Sample 1. [Figure 5B] 1 is an SEM image of the mixed powder for Sample 3. [Figure 5C] 1 is an SEM image of the mixed powder for Sample 4. [Figure 6A] 1 is an SEM image of a larger area of ​​the mixed powder for Sample 1. [Figure 6B] 10 is an SEM image of a larger area of ​​the mixed powder for Sample 3. [Figure 6C] 10 is an SEM image of a larger area of ​​the mixed powder for Sample 4. [Figure 7A] 1 is an EDS image (nickel mapping) of the mixed powder for Sample 1. [Figure 7B] 1 is an EDS image (nickel mapping) of the mixed powder for Sample 3. [Figure 7C] 1 is an EDS image (nickel mapping) of the mixed powder for Sample 4. [Figure 8A] 1 is an EDS image (fluorine mapping) of the mixed powder for Sample 1. [Figure 8B] 1 is an EDS image (fluorine mapping) of the mixed powder for Sample 3. [Figure 8C] 1 is an EDS image (fluorine mapping) of the mixed powder for Sample 4. [Figure 9] 1 is a plot showing bond strength for electrodes prepared by electrostatic spray deposition using powders at various mixing times and speeds according to the present disclosure. [Figure 10]1 is an SEM image of composite particles (NCM 622 / PVDF / carbon) deposited on an Al substrate according to the present disclosure. [Figure 11] 1 is an EDS mapping image of composite particles (NCM 622 / PVDF / carbon) deposited on an Al substrate showing the distribution of Ni active particles according to the present disclosure. [Figure 12] 1 is an EDS mapping image of composite particles (NCM 622 / PVDF / carbon) deposited on an Al substrate showing the distribution of carbon particles relative to Ni active particles, according to the present disclosure. [Figure 13] 1 is an EDS mapping image of composite particles (NCM 622 / PVDF / carbon) deposited on an Al substrate showing the distribution of PVDF binder particles relative to Ni active particles according to the present disclosure. [Figure 14] 1 is a plot of resistance versus mixing time for an electrode made by depositing composite particles onto a substrate using ESD. [Figure 15] 1 is a plot of bond strength versus mixing time for an electrode made by depositing composite particles onto a substrate using ESD. DETAILED DESCRIPTION OF THE INVENTION

[0019] Depicted below are exemplary methods and machines for forming and deploying composite particles in electrochemical energy storage devices, such as rechargeable batteries. Other particle deposition approaches may be used to couple the composite particles to current collectors or other energy storage devices that store and release electrical energy (electrons) to provide electrical current in a controlled and efficient manner.

[0020] As used herein, the term "particle" generally refers to a granular quantity of particulate matter adapted to mix and interact with other particles. Particle morphology may be spherical or any other form. Examples referencing individual particles are intended to be illustrative of the particle's presence, or interactions affecting some or all of it, in a granular quantity of particles, including powder and granular forms. It should further be noted that in battery terminology, "active charge material" is often referred to as "electrochemically active material" or "electrode active material." Electrostatically deposited materials so deposited as disclosed herein may also be referred to as "coating layers," depending on the context.

[0021] Particle agglomeration often occurs in bulk granular materials, including electrochemically active materials, binder materials, and conductive materials involved in the fabrication of electrochemical energy storage devices according to the present disclosure. All of these materials take the form of particles, which may also be in the form of aggregates, meaning multiple primary particles interacting through relatively weak forces that are broken down through agitation and mixing. In general nomenclature, aggregates refer to secondary particles, which are broken down into primary particles or subparticles upon agitation. While the processes and methods discussed herein generally function to form individual primary particles from broken, agitated, or stirred subparticles of aggregates, particles as defined herein include primary particles, secondary particles, subparticles of aggregates, and any interactions or bonds between particles of a particular type. In other words, clusters of primary particles, often referred to as secondary particles or aggregates, are generally expected to separate into smaller particles upon agitation, although certain aggregates remain intact and may still define particles of the respective active material, binder, or conductive material, meaning that particle and / or its subparticles in any form. Thus, a particle may be broken down into multiple subparticles, each of which is still a particle. Additionally, the force applied during the agitation process may be sufficient to break up agglomerated particles.

[0022] Figure 1 is a diagram of the composite particles disclosed herein. The configurations herein apply a solvent-free (dry) electrostatic spray deposition (ESD) coating technique for battery composite electrode fabrication with high uniformity. The present disclosure further enables a composite powder mixing process to produce a composite powder mixture suitable for ESD electrode coating. Alternative applications include any electrochemical storage device, such as a fuel cell.

[0023] A battery has a cathode and an anode. In a typical Li-ion battery, the cathode and anode are based on a composite electrode powder mixture. The composite electrode powder mixture generally contains active electrode material particles (AM), binder material particles (binder), and conductive material particles (CB). The active electrode material may be a cathode material, such as lithium metal oxide-based cathode materials: NCM (lithium nickel cobalt manganese oxide), LMO (lithium manganese oxide), NCA (lithium nickel cobalt aluminum oxide), LCO (lithium cobalt oxide), and lithium polyanion-type cathode materials: LFP (lithium iron phosphate), LiMn x Fe 1-x PO4, Li2FeSiO4, as well as carbonaceous anode materials, graphite, Si, Si-based composites, SiO x In a typical sodium-ion battery, the cathode material is a sodium transition metal oxide, e.g., a sodium-ion battery. 2 / 3 Fe 1 / 2 Mn 1 / 2O2, sodium polyanion materials such as Na2MnSiO4, and Prussian Blue Analogues cathode materials such as Na2MnFe(CN)6. Anode materials include carbonaceous anodes, materials capable of forming an alloy with sodium, sodium transition metal oxides, or Prussian Blue Analogues anode materials. Transition metal oxide-based cathode materials, such as NCM, have been used for 10 -6 ~10 -7 It is a semiconductor with an electronic conductivity of 100 S / cm.

[0024] Typical binder materials are polymeric materials such as PVDF (polyvinylidene fluoride), PTFE (polytetrafluoroethylene), PEO (polyethylene oxide), or PMMA (poly(methyl methacrylate)), SBR (polystyrene butadiene rubber binder), CMC (carboxymethyl cellulose binder), or PAA (polyacrylic acid), which are electrical insulators. The binder material may also be a polymer electrolyte, such as a PEO / lithium triflate polymer electrolyte. Furthermore, the binder may be a solid-state electrolyte composite consisting of an inorganic solid electrolyte and a polymeric binder, a polymer electrolyte binder, or an organic binder, such as a Li3InCl6 / PMMA composite or an LLZO / polymer electrolyte composite.

[0025] The conductive material may include carbon black (CB), carbon nanotubes, or graphene, which are electrically conductive. In addition, some functional additives may be included in the composite electrode. These additives may be, for example, silica, alumina, zirconium oxide, or any combination thereof.

[0026] The true density of the cathode material is generally 4-5 g / cc for NCM and 3.6 g / cc for LFP. The true density of the binder is typically in the range of 1-2 g / cc. Typical particle sizes for the active material are in the range of 1-40 μm. The binder material typically has a primary particle size of 100-1000 nm and an aggregate size of 5-30 μm. The conductive material typically has a primary particle size of 40-80 nm. The conductive current collector is typically Al foil or Cu foil, with or without a prime layer to enhance adhesion between the coated layer and the conductive substrate. Such an adhesion layer may be applied to the conductive substrate prior to deposition.

[0027] Referring to FIG. 1 , an electrode formed by electrostatic spray deposition (ESD) for an electrochemical energy storage device according to the present disclosure includes a plurality of composite particles adapted for electrostatic deposition onto a conductive current collector substrate. Each composite particle of the plurality of composite particles (or at least a majority of the composite particles) includes an active material particle and a binder particle surrounding the active material particle. According to the present disclosure, the binder particles are formed either by breaking down binder agglomerates into subparticles or by directly introducing pre-formed subparticles. In either case, the binder particles adhere to the surfaces of the active material particles through binding forces greater than the interaction forces broken during such agitation, based on forces introduced into the system through agitation of the binder agglomerates. A conductive additive may be added to form the composite.

[0028] In FIG. 1 , the particles in area 100 depict an example cathode material for an electrochemical energy storage device. In a composite electrode powder mixture, the weight ratio of active material is typically greater than 80%, and the weight ratio of binder and conductive material is less than 20%, to enable sufficient gravimetric energy density and acceptable / useful power density for a battery. The composite electrode powder mixture is prepared by a mixing process to enable uniform dispersion of the component particles. FIG. 1 illustrates several dispersion patterns of component particles 101A, 101B, and 101C in a composite electrode powder mixture thoroughly mixed through dry mixing. The component particles include AM, binder, and conductive particles; however, as will become clear in the following discussion, in some configurations, conductive materials are not required and / or included in the composite electrode.

[0029] Generally, the AM particles 111 are the largest particles, the binder particles 112 are smaller but vary (shown as hatched shading), and the conductive particles 113 (shown as solid lines) are in the smallest particle size range. However, in certain embodiments, the sizes and size relationships can vary widely. In particles 101A, the binder 112 either has a large subparticle size or is in the form of aggregates. The active material 111 particles retain their original morphology during dry mixing. In the static powder form, all particles are well dispersed, but there is no strong interaction between the AM 111, binder 112, and CB (conductive) particles 113.

[0030] Particles 101B show that binder 112 agglomerates are advantageously broken in the mixing process, and the subparticle size is smaller than that of the active material 111. The active material particles retain their original morphology during dry mixing. With 101A, in static powder form, particles 111, 112, and 113 may be well dispersed, but there are no strong interaction forces between the AM, binder, and CB particles.

[0031] Particle 101C depicts a composite particle in which binder agglomerates are broken down during the mixing process, resulting in subparticles 112 smaller in size than the active material particles 111. The active material particles retain their original morphology during mixing. In static powder form, the binder particles and conductive particles are individually coated on the surface of the active material particles through surface fusion, van der Waals attractions, or various potential physical interactions and chemical bonds. Composite particle 101C is adapted for electrostatic deposition onto a current collector substrate based on agitated binder subparticles to break down agglomerates, and the interaction forces are sufficient to withstand separation forces caused by material handling, electrostatic deposition onto a substrate, and post-deposition handling to maintain the morphology of composite particle 101C.

[0032] It should be noted that the significant impact on the binder / active particle ratio related to the deagglomeration of binder particles through the mixing process disclosed herein can be theoretically calculated. Thus, as shown in Table 1 below, an average particle size of 0.1 μm for the binder particles increases the binder / active particle ratio to 53,819, compared to 431 for binder particles that are 0.5 μm and 54 for binder particles that are 54 μm. Thus, the dispersion of binder particles relative to active particles (assumed to be 10 μm) increases by several orders of magnitude according to the present disclosure.

[0033] [Table 1]

[0034] A wide variety of AM particle and composite particle formulations can be achieved. It should be noted that a distinction is made between component particles of AM, binder, and conductive material, which are generally obtained as a uniform bulk granular material, and composite particles formed for electrostatic deposition, which are formed by particle-particle interaction forces. In an exemplary arrangement, an active material is formed from a transition metal oxide for use in an electrochemical energy storage device as a cathode material. Typical cathode materials include NCM (lithium nickel cobalt manganese oxide), LFP (lithium iron phosphate), LCO (lithium cobalt oxide), or other suitable formulation chemistries, typically based on the form capable of accepting and releasing lithium ions. Cathode materials can often be formulated prior to deposition by proprietary methods, as opposed to bulk products. The active material formed by the disclosed methods can also be an anode material for electrochemical energy storage devices. Exemplary applications of the active material are for rechargeable batteries, with chemistries defined by rechargeable lithium batteries, Li-ion batteries, rechargeable Li-S batteries, solid-state batteries, rechargeable sodium batteries, and sodium-ion batteries. The binder particles are generally formed from one or more of polymeric materials, polymer electrolytes, and solid state electrolyte complexes, several specific compounds being named above.

[0035] FIG. 2 shows a context / example system for deploying the composite particles of FIG. 1 into a battery. The ESD manufacturing method 200 includes an electrostatic deposition applicator 215 and a hopper 216. A feedstock 214 includes a bulk amount of the composite particles 101C described above. The composite particles 101C are generated by a mixer 130 having an agitator 132 or a similar approach for mixing, combining, and depositing the composite particles 101C. The bulk particle source includes active material 150-1, binder particles 150-2, and optional conductive particles 150-3 (generally 150). The source 150 is fed to the mixer 130 in a predetermined amount, typically at least 80% by weight of active material. The source 150 is typically obtained as a uniform bulk stock from any suitable commercial or industrial source and may have a granular, particulate, or powder structure. Particles and powders should be considered interchangeable in the discussion herein.

[0036] After mixing, the binder particles are typically between 200-1000 nm and the conductive particles are between 100-500 nm. Once mixed, the mixer 130 contains the composite electrode mix 160 for the feedstock 214. The AM particles are typically considerably larger than the attached binder and conductive particles, generally ranging from 1-40 μm, as discussed further below.

[0037] As shown in Figure 2, the composite particles of Figure 1C are depicted as constituent particles for a cathode material in an electrostatic deposition apparatus 250. The active material can be either a cathode material or an anode material, formed from cathode material or anode material particles, respectively. Composite particles from a feedstock 214 are aerated and fluidized by a pressurized gas flow, typically dry air. The fluidized composite particles are carried by the gas flow through an electrostatic applicator 215, where they are charged, move through an electric field, and are ultimately deposited on a grounded conductive current collector 254 to form a composite particle layer 252. The composite particles, fluidized and carried by the gas flow, are charged by corona or triboelectric charging in the electrostatic applicator 215.

[0038] The output product of the electrostatic deposition manufacturing method 200 is a coated sheet 253 comprising a composite particle layer 252 and a substrate 254. The electrostatic deposition applicator 215 can be any suitable electrostatic deposition device. While a spray process is often involved, other electrostatic deposition approaches may be employed. The coated sheet 253 is densified to form an electrode for an electrochemical energy storage device. The coated sheet 253 can also be preheated prior to densification. The densification process can be performed with or without heating. A cathode or an anode can be produced by the above process. The densification process can be repeated, for example, multiple times. For electrostatic charging of the composite particles, the electrostatic applicator can use any suitable electrostatic approach. Electrostatic application can include corona charging, tribocharging, direct electrode induction charging, or other suitable charging processes.

[0039] Electrochemical energy storage devices, such as Li-ion batteries, have a cathode, an anode, a separator, and an electrolyte. The cathode typically contains an active material, such as NCM, a binder material, such as PVDF, and a conductive material, such as carbon black. The anode typically contains an active material, such as graphite, a binder material, such as PVDF or SBR / CMC binder, and / or a conductive material, such as carbon black. The separator is typically a porous polymer film that separates the cathode and anode and allows ion transport between them. The electrolyte is typically a lithium salt solution, such as LiPF6 salt in EC / DMC / EMC solvent, and provides ionic conduction between the cathode and anode.

[0040] In the load or discharge mode, the anode undergoes oxidation and the cathode undergoes reduction. In the charge mode, the anode undergoes reduction and the cathode undergoes oxidation. The energy stored in an electrochemical storage device depends not only on the electrochemical energy stored by the active material but also on the content of the active material in the electrodes. Furthermore, the uniformity of current distribution in an electrochemical energy storage device significantly affects the cycle life of the device. The uniformity of current distribution is directly related to the uniformity of the electrodes. The structural characteristics of the electrodes, such as porosity and thickness, affect the power capacity of an electrochemical energy storage device.

[0041] Characteristics affected by forming and layering the charged material include the uniformity of the electrode, the active material loading in the electrode, the porosity of the electrode, the electrical conductivity, the processability of the electrode, the power density and cycle life of the resulting battery, which directly relate to the energy density.

[0042] In electrostatic processing 200, the charge on the particles is calculated according to the following formula:

[0043]

number

[0044] Typical particle size ranges for cathode materials are in the range of 1-40 μm. Typical primary particle sizes for PVDF binders are 200-300 nm. Typical primary particle sizes for conductive carbons are 40-50 nm. From the above equation, the maximum charge on a particle is directly related to the square of the particle radius, so the charge on individual powder components during electrostatic deposition can vary by several orders of magnitude.

[0045] Cathode materials typically have a much higher dielectric constant than polymeric binder materials: for example, PVDF has a dielectric constant of about 8-10 at 21°C, while lithium nickel oxide-based cathode materials have a dielectric constant of the order of 1000.

[0046] The relaxation time t for charge dissipation from an ideal charged body is τ=ε0ε r / σ (In the formula, ε r = relative permittivity of the powder, and σ = electronic conductivity of the powder) is given by

[0047] The electronic conductivity of NCM cathode materials is generally 10 -6 ~10 -7 S / cm, and PVDF is 10 -14 S / cm, which results in a difference of several orders of magnitude in the relaxation time for charge dissipation.

[0048] Based on the above analysis, active material particles, binder particles, and conductive material particles have different electrostatic deposition behaviors in the electrostatic deposition process due to significant differences in chargeability and charge dissipation time resulting from differences in conductivity, dielectric constant, particle size, and density.

[0049] In addition, differences in particle size, particle density, morphology, surface roughness, and therefore surface energy will cause them to behave differently as they relate to aerodynamic effects during powder fluidization and mechanical transport to the surface to be coated.

[0050] In the absence of strong interaction forces between particles in the mixture, significant segregation can occur during coating due to differences in electrostatic deposition and fluidization behavior related to powder properties, leading to detrimental effects on coating uniformity in terms of composition, microstructure, and dimensions. Conventional approaches result in a deposited layer 252 with varying stoichiometry due to different deposition patterns from the individual component particles, for example, from the feedstock 214.

[0051] In electrostatic deposition process 200 using conventional techniques, active material particles, binder particles, and conductive material particles (formed as 101A and 101B) are individually charged as the powder particles pass through a space charging zone in a corona charging, tribocharging, or direct flat-plate electrode electrostatic charging system. Due to differences in chargeability and charge dissipation time, the individually charged particles deposit on the current collector, causing non-uniformity in the deposited layer.

[0052] During the formation of composite particles 101C according to the present disclosure, small binder particles and conductive material particles are attached / adhered to the surfaces of active material particles to form composite particles. During aeration or mechanical transport and deposition of the composite particles, consisting of active material particles with binder and conductive material particles attached to their surfaces, the composite particles become charged and accumulate, resulting in a uniform deposition on the current collector substrate 254. Furthermore, due to the high resistivity of the binder particles 112, the charge dissipation time of the composite particles is longer than that of pure active material particles, which allows electrostatic forces to be effective during handling after coating until the binder curing operation can be performed. Therefore, the composition of composite particles 101C in the feedstock 214 electrode powder mixture is particularly beneficial for electrostatic deposition to achieve a high degree of uniformity.

[0053] 3A and 3B show example compositions of the composite particle of FIG. 1. Referring to FIGS. 1 through 3A-3B, FIG. 3A shows composite particle 101C having AM particles 111 and attached binder particles 112. FIG. 3B shows that composite particle 101C further includes conductive particles 113. Depending on the arrangement of mixer 130, composite particle 101C can be formed from simultaneously mixing conductive particles 113, active material particles 111, and binder particles 112. In an alternative configuration, composite particle 101C further includes combining conductive particles 113 to adhere to the surfaces of binder particles 112, and subsequently adhering the combined binder and conductive particles to the surfaces of AM particles 111, thereby forming composite particle 101C.

[0054] Any mixing / particle coating equipment, such as an impact mixer or shear mixer, can be used to achieve the composite electrode powder mixture formed in composite particle 101C. Binder agglomerates are broken down to form sub-particles, and conductive material agglomerates are broken down into smaller particles. These sub-particles attach / adhere to the surfaces of the active material particles through surface fusion, van der Waals attractions, or a variety of potential physical interactions or chemical bonds, creating a sufficiently large interaction force between the individual particles to form an effective composite particle that can overcome particle separation during electrostatic charging, fluidization, mechanical transport, and / or deposition processes.

[0055] FIG. 4 illustrates the progression through the formation of the composite particle (e.g., composite particle 101C) of FIGS. 1-3B. An important characteristic of mixing and agitation is to break down binder agglomerates 112′ into subparticles 112, if such agglomerates are present in the raw material source. Agitation also reduces the conductive particles 113′ into smaller subparticles 113 that are better suited for attachment to the AM particles 111. The mixing / agitation disclosed herein is sufficient to break the interaction forces 401 between the agglomerates and yet adhere the binder 112 to the AM particles 111 with bonding forces 402 that are greater than the separation forces encountered through the electrostatic deposition system 200, thereby maintaining the morphology of the composite particle 101C and providing uniform deposition of layer 252.

[0056] The sizes shown in FIG. 4 are for illustrative and example purposes only. In actual production, the size of the binder subparticles 112 is expected to range between 0.1% and 70% of the average size of the active material particles 111. When the average particle size of the active material is greater than 5 μm, it is beneficial if the average subparticle size of the binder is less than 10% of the active material. When the average particle size of the active material is less than 5 μm, the preferred average subparticle size of the binder is less than 70% of the active material.

[0057] Granular feedstock 150 can be expected to exhibit particle size variations, and generally is expected and normal to be in a range of sizes. As long as the overall range exhibits a typical distribution and average, stray particles outside the ranges set forth herein are unlikely to have a negative effect. Similar distribution ranges are acceptable for the agglomerates and subparticles discussed above, and not all agglomerates / secondary particles can always be expected to be broken down with strict uniformity.

[0058] The subparticle size of the conductive material is 1 to 100% of the average subparticle size of the binder. Preferably, the subparticle size of the conductive material is less than 30% of the average subparticle size of the binder. Not all of the binder 112 and conductive particles 113 from the constituent or component particles may adhere to the active material particles 111. In the electrode powder mixture, more than 50% by weight of the binder subparticles should be applied to the surfaces of the active material particles. Preferably, more than 80% by weight of the binder subparticles are applied to the surfaces of the active material particles. More than 50% by weight of the conductive subparticles are applied to the surfaces of the binder subparticles. And, more than 50% of the binder / conductive composite particles are applied to the surfaces of the active material particles. Preferably, more than 80% by weight of the binder and conductive material are applied to the surfaces of the active material particles.

[0059] When the composite electrode mix does not contain a conductive material, the binder subparticles are applied directly to the surfaces of the active material particles.

[0060] The active material powder, binder powder, and / or conductive material powder can be simultaneously charged into a mixer and mixed. It is preferable to premix the binder and conductive material and then mix them with the active material powder, so as to better break down binder and conductive aggregates and increase the interaction between the binder subparticles and the conductive material.

[0061] Some additional particle stock sizings are as follows: The subparticle size of the conductive material is 1-100% of the average subparticle size of the binder. Preferably, the subparticle size of the conductive material is less than 30% of the average subparticle size of the binder.

[0062] In alternative arrangements, the method of applying / attaching the binder / conductive particles to the active material particles is not limited to the dry powder mixing described herein. For example, in one exemplary embodiment, the binder / conductive material particles can be coated onto the active material particles through mixing a suspension or solution of the binder / conductive material with the active material powder. In another exemplary embodiment, the binder particles can be coated onto / to the surfaces of the active material particles through a spray drying process.

[0063] In a specific use case, the mixer 130 uses a high-shear mixer to mix an NCM / binder / CB powder mixture with standard binder subparticle sizes for electrostatic deposition. The high-shear mixer features a unique rotating mixing pan with built-in eccentric mixing tools. Mixing speeds can be set between 1 and 30 m / s to disperse and mix particles of different sizes. In this example, an active material (NCM) with a size of approximately 10 μm, a PVDF binder with a primary size of 200 to 300 nm, and a conductive carbon with a primary size of 40 to 50 nm were used. The AM / binder / CB particles with a weight ratio of 96:2:2 were mixed for 30 minutes using the high-shear mixer. SEM imaging of the mixed particles shows a coating of CB and binder on the surface of the AM. [Example]

[0064] 1. Material Preparation and Electrode Preparation by Electrostatic Spray Deposition A 700 g batch of powder mixture containing heat-treated NMC, PVDF, and carbon black in a weight ratio of 90:7:3 was loaded into a high-shear mixer. Mixing studies were conducted at different mixing speeds and times (Sample 1: 12 m / s, 10 min; Sample 3: 20 m / s, 20 min; Sample 4: 25 m / s, 20 min).

[0065] The mixed NMC powder was loaded into a hopper in an electrostatic spray deposition system. The dry powder was fluidized by conveying gas under vibration. The fluidized powder was charged by a corona electrostatic spray gun and deposited onto a 15 μm-thick grounded Al foil. The coated side of the Al foil was pre-coated with a PVDF interface layer with a thickness of less than 1 μm, applied by electrostatic spray deposition technique. The deposited sample was heated at 250 °C on a hot plate for approximately 1 hour to melt the binder. Finally, the annealed sample was pressed to the desired thickness using a roller press to achieve 35% porosity. The electrode sample was ready for SEM / EDS, adhesion, and electrochemical testing.

[0066] 2. SEM / EDS examination of samples 1, 3 and 4 The mixed powder samples were analyzed by SEM / EDS to evaluate the deagglomeration of the PVDF / carbon particles and the coating of PVDF / carbon on the NMC particles. As shown in Figure 5A, slight agglomerates of PVDF / carbon can be seen attached to the NMC surface, but most of the NMC surface is exposed. The structure of the NMC surface is clearly visible. This indicates that under 12 m / s, 10 min of mixing, the surface of the NMC is barely covered by the PVDF / carbon particles.

[0067] As the mixing intensity increases to 20 m / s for 20 min (Sample 3, Figure 5B) and 25 m / s for 20 min (Sample 4, Figure 5C), the surface of the NMC particles is completely covered by PVDF / carbon.

[0068] 6A-6C show SEM images of larger areas of the mixed powder for Sample 1 (FIG. 6A), Sample 3 (FIG. 6B), and Sample 4 (FIG. 6C).

[0069] The corresponding EDS results are shown in Figure 7A (Sample 1, nickel mapping), Figure 7B (Sample 3, nickel mapping), and Figure 7C (Sample 4, nickel mapping), as well as Figure 8A (Sample 1, fluorine mapping), Figure 8B (Sample 3, fluorine mapping), and Figure 8C (Sample 4, fluorine mapping). ImageJ was used to process the elemental mapping images to remove the effect of signal intensity on image quality. The maximum intensity of each element is reported in the images.

[0070] As shown in Figures 7A-7C, the nickel distribution can be fully mapped relative to the corresponding SEM images. The overall shape of individual NMC particles is captured by the nickel mapping. Fluorine mapping, an indicator of PVDF content (Figures 8A-8C), shows striking differences between the three blends.

[0071] The fluorine mapping image (Figure 8A) of the 12 m / s, 10 min mixing does not reveal the generally spherical shape of the NMC particles, indicating that most of the PVDF particles are still randomly positioned in the mixed powder rather than attached to the NMC particles. The tightly packed black spots (indicated by arrows) near the bottom left corner of the image also indicate that some PVDF particle agglomerates were not broken down under low-intensity mixing.

[0072] With more intense mixing, the fluorine begins to concentrate, revealing the spherical shape of the NMC particles, as shown at 20 m / s, 20 min (Sample 3, Figure 8B) and 25 m / s, 20 min (Sample 4, Figure 8C). The tightly packed dark spots (indicated by arrows) near the center-left of the fluorine mapping for 20 m / s, 20 min mixing (Sample 3, Figure 8B) indicate large agglomerates of PVDF particles. The corresponding SEM image in Figure 6B shows that the NMC particles are visible behind these large agglomerates of PVDF particles, but the PVDF agglomerates completely block the nickel x-ray spectrum collected by the detector. Therefore, they appear as spaces (indicated by arrows) in the corresponding nickel mapping image. Large PVDF agglomerates are not visible in the powder mixed at 25 m / s, 20 min (Sample 4). A relatively uniform distribution of PVDF particles is achieved, as seen in the corresponding fluorine mapping image in Figure 8C.

[0073] 3. Adhesion test The bond strength of the electrodes was evaluated using a pull-off test. The electrode samples were cut into disks with a diameter of 14.3 mm. The electrode disks were attached to a flat head tip with a diameter of 12.7 mm using double-sided tape. The disks were attached to the base with the double-sided tape using a compressive force of 15 N and then pulled, and the maximum tensile force that resulted in the disk's collapse was recorded. Figure 9 is a plot showing the bond strength for electrodes prepared by electrostatic spray deposition using powders at various mixing times and speeds, i.e., Samples 1, 3, and 4. The plot in Figure 9 shows that samples prepared with longer mixing times demonstrated better adhesion.

[0074] 4. EDS Mapping of Electrodes In a further exemplary embodiment of the present disclosure, binder particles were subjected to deagglomeration to form the composite particles described hereinabove, and the composite particles were deposited onto an aluminum foil substrate by electrostatic spray deposition, followed by thermal calendering. This exemplary embodiment has a binder content of 20 mg / cm 2The composite particles in the electrode are made from NCM 622 / PVDF / carbon with a loading of 0.01g / cc and a density of 3.7g / cc. The PVDF and carbon interact with the active particles to provide strong adhesion and electrical conductivity.

[0075] As shown in the SEM images in Figure 10, the composite particles exhibit strong adhesion to the Al substrate.

[0076] As shown in the EDS mapping image in Figure 11, the Ni active particles are uniformly distributed and adhere to the Al substrate.

[0077] As shown in the EDS mapping image in FIG. 12, the carbon particles are uniformly distributed and adhere to the Ni active particles.

[0078] As shown in the EDS mapping image in Figure 13, the PVDF binder particles are uniformly distributed and adhered to the Ni active particles (based on the imaging method showing the fluorine distribution).

[0079] 5. Results of the Mixing Study A series of tests were conducted to determine the relationship between the mixing conditions related to the formation of composite particles and the performance of these composite particles when deposited onto a substrate by ESD. A 700 g batch of powder mixture containing heat-treated NMC, PVDF, and carbon black in a weight ratio of 96:2:2 was loaded into a high-shear mixer. Mixing studies were conducted using various mixing speeds and times. The resistance across the thickness of the fabricated electrodes was measured by sandwiching the electrode disc between two measuring plates.

[0080] As shown in the plot of Figure 14, the resistance associated with the composite particles deposited on the substrate (which is a measure of the uniformity of carbon distribution for the composite particles deposited on the substrate) indicates that a favorable operating window is established for mixing times between about 8 and 35 minutes. Mixing times less than 8 minutes resulted in unacceptably high resistance levels (approximately 33 ohms). Significantly longer mixing times (approximately 50 minutes) did not improve results, but rather demonstrated approximately equivalent resistance performance when compared to shorter duration mixing, e.g., approximately 30 minutes.

[0081] Turning to Figure 15, bond strength (which is a measure of the uniformity and effectiveness of binder distribution for composite particles deposited on a substrate) associated with composite particles deposited on a substrate indicates that a favorable operating window is established for mix times between about 8 and 35 minutes—the same operating window identified by the resistance measurements described above with reference to Figure 14. Mix times less than 8 minutes resulted in unacceptably low bond strengths. Significantly longer mix times (approximately 50 minutes) did not improve results, but rather demonstrated approximately equivalent average bond strengths and a much broader range of performance when compared to mixes of shorter duration, e.g., approximately 30 minutes.

[0082] Based on the test results shown in FIGS. 14 and 15, a mixing time between about 8 minutes and about 35 minutes is effective in forming composite particles exhibiting good distribution and maintaining adhesion / attachment of the binder particles and conductive particles to the active particles according to the present disclosure.

[0083] The disclosed electrochemical energy storage devices can be incorporated into various assemblies / subassemblies, such as rechargeable lithium batteries, Li-ion batteries, rechargeable lithium-sulfur batteries, solid state batteries, rechargeable sodium batteries, and / or sodium-ion batteries.

[0084] While the systems and methods defined herein have been particularly shown and described with reference to embodiments thereof, those skilled in the art will understand that various changes in form and details may be made therein without departing from the scope of the invention as encompassed by the appended claims. The present invention includes the following aspects. [Section 1] a conductive current collector substrate; One or more electrostatically deposited coating layers deposited on and adhered to a conductive current collector substrate. An electrode comprising: the one or more electrostatically deposited coating layers comprise a plurality of dry mixed composite particles, each dry mixed composite particle of the plurality of dry mixed composite particles comprising: (i) one or more active material particles; and (ii) deagglomerated binder particles surrounding each of the one or more active material particles; the deagglomerated binder particles adhere to the surface of one of the one or more active material particles through interactions sufficient to withstand the mixing involved in forming the dry composite particles and to overcome separation forces resulting from the deposition of one or more electrostatically deposited coating layers on the conductive current collector substrate; This allows the structure of the composite particles to be maintained when applied onto a conductive current collector substrate, an electrode. [Section 2] Item 14. The electrode of item 1, wherein one or more active material particles function as a cathode material. [Section 3] Item 3. The electrode of item 2, wherein the one or more active material particles are selected from (i) lithium transition metal oxides, lithium transition metal sulfides, lithium polyanion cathode materials including lithium transition metal phosphates, lithium transition metal silicates, or combinations thereof, or (ii) sodium transition metal oxides, sodium polyanion cathode materials, Prussian blue analog cathode materials, or combinations thereof. [Section 4] Item 14. The electrode of item 1, wherein one or more active material particles function as an anode material. [Section 5] The one or more active material particles are selected from the group consisting of: (i) a carbonaceous anode material, graphite, Si, Si-based composites, and SiO x Item 5. The electrode of item 4, wherein the anode material is selected from (i) a material capable of alloying with lithium, or a lithium transition metal oxide anode material, or a combination thereof; or (ii) a material capable of alloying with sodium, or an ion intercalation anode material, including a Prussian blue analog anode, and a sodium metal transition metal oxide anode. [Section 6] Item 1, wherein the electrode is incorporated into an assembly selected from the group consisting of a rechargeable lithium battery, a Li-ion battery, a rechargeable lithium-sulfur battery, a solid-state battery, a rechargeable sodium battery, and a sodium-ion battery. [Section 7] Item 10. The electrode of item 1, wherein the deagglomerated binder particles are formed from one or more of a polymeric material, a polymer electrolyte, and a solid-state electrolyte complex. [Section 8] 8. The electrode of paragraph 7, wherein the polymeric material is selected from polyvinylidene fluoride, polytetrafluoroethylene, polyethylene oxide, poly(methyl methacrylate), polystyrene butadiene rubber binder, carboxymethyl cellulose binder, polyacrylic acid, or combinations thereof. [Section 9] Item 10. The electrode according to item 1, wherein the dry-mixed composite particles further comprise conductive particles attached to a surface of at least one of the one or more active material particles and the deagglomerated binder particles. [Section 10] Item 10. The electrode according to item 9, wherein the conductive particles are selected from the group consisting of carbon black, carbon nanotubes, carbon fibers, graphene, graphite, or combinations thereof. [Section 11] Item 1. The electrode according to item 1, wherein the conductive current collector substrate is selected from Al or Cu foil. [Section 12] Item 12. The electrode of item 11, further comprising a prime layer to enhance adhesion between the one or more electrostatically deposited coating layers and the conductive current collector substrate. [Section 13] Item 1. The electrode according to item 1, wherein the size of the deagglomerated binder particles is between 0.1% and 70% of the average size of the one or more active material particles. [Section 14] Item 1. The electrode of item 1, wherein the average size of the one or more active material particles is greater than 5 μm, and the average size of the deagglomerated binder particles is less than 10% of the average size of the one or more active material particles. [Section 15] Item 1. The electrode according to item 1, wherein the average size of the one or more active material particles is less than 5 μm, and the average size of the deagglomerated binder particles is less than 70% of the average size of the one or more active material particles. [Section 16] Item 1. The electrode according to item 1, wherein the dry-mixed composite particles further comprise conductive particles, and more than 50% of the deagglomerated binder particles and conductive particles are attached to an active material particle among the one or more active material particles. [Section 17] 1. A method of forming an electrode, comprising: combining one or more active material particles and deagglomerated binder particles to form a plurality of dry mixed composite particles, wherein the deagglomerated binder particles surround each of the one or more active material particles; depositing the plurality of dry mixed composite particles onto a surface of a conductive substrate by an electrostatic deposition process; A method comprising: [Section 18] deagglomerating the binder material to form deagglomerated binder particles. Item 18. The method of item 17, further comprising: [Section 19] combining conductive particles with one or more active material particles and deagglomerated binder particles, wherein the conductive particles adhere to surfaces of the deagglomerated binder particles; and followed by adhering the combined binder and conductive particles to the surface of one or more active material particles to form composite particles. Item 18. The method of item 17, further comprising: [Section 20] Item 18. The method of item 17, wherein the electrostatic deposition process is selected from the group consisting of corona-charged electrostatic deposition, tribo-charged electrostatic deposition, and direct electrode-induced electrostatic deposition. [Section 21] 18. The method of claim 17, wherein deagglomerated binder particles are formed from the binder material by combining one or more active material particles and a binder material and agitating the dry mixture to overcome cohesive forces and form deagglomerated binder particles from the binder material, whereby the deagglomerated binder particles adhere to the surface of the one or more active material particles to form composite particles having sufficient interaction between the deagglomerated binder particles and the one or more active material particles to maintain adhesion during electrostatic charging, fluidization, and mechanical transport. [Section 22] 22. The method of claim 21, wherein the stirring provides sufficient force to pulverize the dry mixture. [Section 23] Adhering the plurality of dry-mixed composite particles to the surface of the conductive substrate includes depositing the plurality of composite particles on the conductive substrate to form a coating layer having a predetermined active material loading; (i) preheating the coating layer and the conductive substrate followed by a densification treatment; (ii) preheating the coating layer and the conductive substrate followed by densification under heat; and (iii) densifying the coating layer and the conductive substrate under heat. Item 22. The method according to item 21. [Section 24] Item 24. The method according to item 23, wherein the densification treatment is repeated. [Section 25] 22. The method of claim 21, wherein the agitation results in deagglomerated binder particles with a size between 200 and 1000 nm. [Section 26] 18. The method of claim 17, wherein the combining step includes combining the conductive particles with one or more active material particles and deagglomerated binder particles to form a plurality of dry-mixed composite particles, whereby the conductive particles adhere to the deagglomerated binder particles. [Section 27] deagglomerated binder particles are formed from the binder material by combining one or more active material particles and the binder material and agitating the dry mixture to overcome cohesive forces and form deagglomerated binder particles from the binder material; the structure of the one or more active particles is maintained during agitation and attachment to the surface of the conductive substrate; deagglomerated binder particles are formed by deagglomerating binder material; combining the one or more active material particles and the deagglomerated binder particles to form a plurality of dry mixed composite particles includes agitating the one or more active material particles and the deagglomerated binder particles in a solvent-free manner to adhere the deagglomerated binder particles and to maintain the morphology of the one or more active material particles during agitation; Item 18. The method according to item 17. [Section 28] combining the deagglomerated binder particles with the conductive particles such that the conductive particles adhere to the deagglomerated binder particles; and Adhering the combined deagglomerated binder particles and conductive particles to the surface of one or more active material particles to form dry mixed composite particles. further comprising the dry mixed composite particles have less than 20 weight percent of the combined conductive particles and deagglomerated binder particles, and the average size of the binder particles is less than 50% of the average active material particle size; the average size of the conductive particles is less than 30% of the average size of the deagglomerated binder particles; Item 18. The method according to item 17. [Section 29] Item 18. The method of item 17, further comprising forming an electrode from the conductive substrate having the dry mixed composite particles attached thereto. [Section 30] Item 18. The method of item 17, further comprising including in the battery a conductive substrate having the dry mixed composite particles adhered thereto.

Claims

1. a conductive current collector substrate; An electrostatically deposited coating layer deposited on and adhered to a conductive current collector substrate. An electrode comprising: the electrostatically deposited coating layer comprises a plurality of dry mixed composite particles, the plurality of dry mixed composite particles comprising (i) active material particles and (ii) deagglomerated binder particles; An electrode, wherein the deagglomerated binder particles and the active material particles are mixed prior to deposition on a conductive current collector substrate to form a plurality of dry-mixed composite particles, with the deagglomerated binder particles surrounding each of the active material particles.

2. The electrode of claim 1, wherein the active material particles function as a cathode material.

3. An electrode as described in claim 2, wherein the active material particles are selected from (i) lithium transition metal oxides, lithium transition metal sulfides, lithium transition metal phosphates, lithium polyanion cathode materials, lithium transition metal silicates, or combinations thereof, or (ii) sodium transition metal oxides, sodium polyanion cathode materials, Prussian blue analog cathode materials, or combinations thereof.

4. The electrode of claim 1, wherein the active material particles function as an anode material.

5. The active material particles are (i) a carbonaceous anode material, graphite, Si, a Si-based composite, SiO x 5. The electrode of claim 4, wherein the anode material is selected from (i) a material capable of alloying with lithium, or a lithium transition metal oxide anode material, or a combination thereof; or (ii) an ion intercalation anode material comprising a material capable of alloying with sodium, or a Prussian blue analog anode, and a sodium metal transition metal oxide anode.

6. The electrode of claim 1, wherein the conductive collector substrate having an electrostatically deposited coating layer adhered to the conductive collector substrate is incorporated into an assembly selected from the group consisting of a rechargeable lithium battery, a Li-ion battery, a rechargeable lithium-sulfur battery, a solid-state battery, a rechargeable sodium battery, and a sodium-ion battery.

7. 10. The electrode of claim 1, wherein the deagglomerated binder particles are formed from one or more of a polymeric material, a polymer electrolyte, and a solid-state electrolyte complex.

8. 8. The electrode of claim 7, wherein the polymeric material is selected from polyvinylidene fluoride, polytetrafluoroethylene, polyethylene oxide, poly(methyl methacrylate), polystyrene butadiene rubber binder, carboxymethyl cellulose binder, polyacrylic acid, or combinations thereof.

9. The electrode of claim 1, wherein the plurality of dry-mixed composite particles further comprises conductive particles adhered to a surface of at least one of the active material particles and the deagglomerated binder particles.

10. 10. The electrode of claim 9, wherein the conductive particles are selected from the group consisting of carbon black, carbon nanotubes, carbon fibers, graphene, graphite, or combinations thereof.

11. 10. The electrode of claim 1, wherein the conductive current collector substrate is selected from Al or Cu foil.

12. The electrode of claim 11, further comprising a prime layer to enhance adhesion between the electrostatically deposited coating layer and the conductive current collector substrate.

13. 10. The electrode of claim 1, wherein the size of the deagglomerated binder particles is between 0.1% and 70% of the average size of the active material particles.

14. The electrode of claim 1, wherein the average size of the active material particles is greater than 5 μm and the average size of the deagglomerated binder particles is less than 10% of the average size of the active material particles.

15. The electrode of claim 1, wherein the average size of the active material particles is less than 5 μm and the average size of the deagglomerated binder particles is less than 70% of the average size of the active material particles.

16. An electrode as described in claim 1, wherein the plurality of dry-mixed composite particles further comprise conductive particles, and more than 50% of the deagglomerated binder particles and conductive particles are adhered to one active material particle among the active material particles.

17. A method for forming electrodes for an anode and a cathode, comprising: providing a first source of bulk particles comprising deagglomerated binder particles having a primary particle size of 100 to 1000 nm; providing a second source of bulk particles of active material particles; mixing the deagglomerated binder particles and the active material particles to form a plurality of dry-mixed composite particles, each of which is surrounded by a deagglomerated binder particle; and electrostatically depositing a plurality of dry mixed composite particles onto the surface of a conductive substrate or onto a layer adhered to the surface of a conductive substrate. Including, The method, wherein the active material particles are positive electrode active material particles or negative electrode active material particles.

18. 18. The method of claim 17, wherein the electrostatic deposition process is selected from the group consisting of corona-charged electrostatic deposition, tribo-charged electrostatic deposition, and direct electrode induction-charged deposition.

19. A method of forming a battery, comprising: providing an anode and a cathode; disposing a separator between the anode and the cathode; and Adding an electrolyte to form a battery Including, 20. A method wherein at least one of the anode or cathode is formed by the method for forming an electrode according to claim 17.

20. A method for forming an electrode, comprising: deagglomerating agglomerates of the binder material to form deagglomerated binder particles having a primary particle size of 100 to 1000 nm; mixing the active material particles and the deagglomerated binder particles to form a plurality of dry-mixed composite particles, each of the active material particles being surrounded by the deagglomerated binder particles; and electrostatically depositing a plurality of dry mixed composite particles onto the surface of a conductive substrate or onto a layer adhered to the surface of a conductive substrate. Including, The method, wherein the active material particles are positive electrode active material particles or negative electrode active material particles.

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