Radiation cured electrodes, energy storage devices, and forming methods thereof

Abstract

In this disclosure, energy storage devices (e.g., high voltage energy storage devices) with electrodes formed with radiation (e.g., electron beam) curable binders are described. The electrodes may beneficially be perfluoroalkyl and polyfluoroalkyl free (PFA-free or PFAS-free).

Description

RADIATION CURED ELECTRODES, ENERGY STORAGE DEVICES, AND FORMING METHODS THEREOFINCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet or PCT Request as filed with the present application are hereby incorporated by reference under 37 CFR 1.57, and Rules 4.18 and 20.6. This application claims the benefit of U.S. Provisional Application No. 63 / 668,516, filed on July 8, 2024, which is incorporated by reference herein in its entirety for all purposes.BACKGROUNDField

[0002] The present disclosure generally relates to energy storage devices, such as batteries: thermoelectric and photoelectric, and supercapacitors. More specifically, the present disclosure relates to radiation cured electrode films for use in energy storage devices (e.g., high voltage energy7storage devices, electrochemical devices).Description of the Related Art

[0003] Energy storage devices include batteries, fuel cells, electrochemical sensors (e.g., glucose monitors) and bio-fuel cells. Typical existing energy storage devices (e.g., batteries) may be deficient with regard to several aspects, for example with regard to charge / discharge rates, total energy, power performance, and the rigidity of the energy storage device itself.

[0004] Traditional energy storage device (e.g., battery) manufacturing methods involve slurry-based processes using polymer binders, such as perfluoroalkyl and polyfluoroalkyl (PFA or PF AS) (e.g., poly vinylidene difluoride (PVDF)), dissolved in an organic solvent (e.g., N-Methyl-2-pyrrolidone (NMP)). This solvent-based process requires high energy consumptions from electrode drying, a large equipment footprint, low production speeds and mandatory7solvent recovery7. PF As have been recognized as a class of forever chemicals that have come under increased scrutiny in recent times due to their persistence in drinking water and increased concerns about their potential health effects (e.g., increased risk of cancer, obesity7, birth defects, growth defects, reduce immunefunction), and as such the use of these chemicals have been banned in some areas. Further expected bans of these chemicals would restrict the use of energy storage devices containing these chemicals. In addition, the removal and recovery of organic solvents (e.g., NMP) use as processing solvents accounts for -46% energy consumption on manufacturing. The toxic, flammable and explosive nature of organic solvents makes this a liability.

[0005] Furthermore, such traditional energy storage devices may have a limited energy density due to a lack of electrochemical voltage stability within the active material (e.g., LCO, NMC, LFP) and the electrolyte. As such, improved energy storage devices would be advantageous.SUMMARY

[0006] For purposes of summarizing the disclosure and the advantages achieved over the prior art, certain objects and advantages of the disclosure are described herein. Not all such objects or advantages may be achieved in any particular embodiment. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0007] In one aspect, an electrode film is described. The electrode film includes: an active material; a binder consisting essentially of an electron beam (EB) cured binder; and a conductive additive.

[0008] In some embodiments, the electrode film is substantially free of a perfluoroalkyl and polyfluoroalkyl (PFA). In some embodiments, the active material is a cathode active material. In some embodiments, the cathode active material is selected from manganese dioxide, lithium iron phosphate (LFP), lithium cobalt oxide (LCO), lithium nickel manganese oxide (LNMO), nickel manganese cobalt oxide (NMC), nickel cobalt aluminum oxide (NCA), lithium manganese iron phosphate (LMFP), and combinations thereof. In some embodiments, the cathode active material is LCO, LNMO, and combinations thereof. In some embodiments, the EB cured binder is selected from an acrylated polyurethane resin, a hydroxy modified acrylated polyurethane resin, an acrylatemethacrylate monomer blend, a monoacrylate of mono-ethoxylated phenol, trimethylolpropane ethoxy triacrylate, an acrylonitrile, an acrylamide, co-polymers thereof, and admixtures thereof.

[0009] In some embodiments, the active material comprises an active material particle size of about 1 pm to about 50 pm. In some embodiments, the conductive additive comprises a conductive additive particle size of about 10 nm to about 5 pm. In some embodiments, the electrode fdm further includes a surfactant.

[0010] In another aspect, an electrode is described. The electrode includes: a current collector; and an electrode film described herein disposed over the current collector. In some embodiments, an adhesion strength of the electrode film to the current collector is about 0. 1 N / cm to 10 N / cm.

[0011] In another aspect, an energy storage device is described. The energy storage device includes: an electrode described herein; a second electrode; a separator disposed between the electrode and the second electrode; an electrolyte; and a housing, wherein the electrode, second electrode, separator and electrolyte are disposed within the housing.

[0012] In another aspect, a method of preparing an electrode film is described. The method includes: combining solvent and an electron beam (EB) curable binder to form a first mixture; combining a first amount of an active material with the first mixture to form a second mixture; combining a second amount of the active material with the second mixture to form an electrode film slurry; and exposing the electrode film slurry to an electron beam to form an electrode film.

[0013] In some embodiments, the method further includes combining a conductive additive with the second mixture prior to combining a second amount of the active material with the second mixture. In some embodiments, the first amount of an active material is combined with a conductive additive and the first mixture to form the second mixture. In some embodiments, the electrode film slurry comprises a solids content of at least about 60 wt.%. In some embodiments, the EB curable binder is short chain EB curable binder. In some embodiments, the method further includes high shear mixing the second mixture. In some embodiments, the electrode film slurry comprises a viscosity of about 500 cP to about 50,000 cP.

[0014] In another aspect, a method of forming an electrode is described. The method includes: performing a method of preparing an electrode film described herein; and depositing the electrode film mixture over the current collector prior to exposing the electrode film slurry to an electron beam.

[0015] In another aspect, a method forming an energy storage device is described. The method includes: performing a method of forming an electrode describedherein; and disposing the electrode, a second electrode, a separator and an electrolyte within a housing, wherein the separator is disposed between the electrode and the second electrode.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is an illustration of a perfluoroalkyl and polyfluoroalkyl (PF As) based electrode prior and subsequent to evaporation of volatile organic compound (VOC) solvent.

[0017] FIG. 2 is an illustration of a curable electrode prior and subsequent to electron curing, according to some embodiments.

[0018] FIG. 3 is an illustration of a jellyroll energy storage device with a radiation cured electrode, according to some embodiments.

[0019] FIG. 4A is a graph showing the specific capacity vs. cycle results of an energy storage device pouch cell including traditional LCD and PVDF materials.

[0020] FIG. 4B is a graph showing the specific capacity vs. cycle results of an energy storage device pouch cell including a radiation cured LCO electrode, according to some embodiments.

[0021] FIG. 5A is a graph showing voltage vs. specific capacity results of energy storage devices using a PVDF based electrode and a radiation cured electrode, according to some embodiments.

[0022] FIG. 5B is a graph showing cyclic voltammetry current vs. voltage results of energy’ storage devices using a PVDF based electrode and a radiation cured electrode, according to some embodiments.DETAILED DESCRIPTION

[0023] Although certain embodiments and examples are described below, those of skill in the art will appreciate that the invention extends beyond the specifically disclosed embodiments and / or uses and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the invention herein disclosed should not be limited by any particular embodiments described below.

[0024] In this disclosure, energy storage devices (e.g., high voltage energy storage devices) with electrodes formed with radiation (e.g., electron beam) curable binders are described. The electrodes may beneficially be perfluoroalkyl and polyfluoroalkyl free (PFA-free or PFAS-free). In some embodiments, the radiation curing serves as the energysource to chemically polymerize and crosslink small molecules (i.e. monomers, oligomers, and low molecular weight polymers) into high molecular weight, PFA-free polymers. Therefore, in some embodiments, a minimal amount or even no organic solvent may be required during the coating formulation and deposition of the as-cast electrode film, thereby including a relatively high solids content. The minimization and / or elimination of solvent in the process can remove or reduce the reliance on a solvent recovery unit relative to the traditional process, which not only reduces the facility footprint, but also decreases energy consumption. In addition, the minimization and / or elimination of solvent reduces the reliance on harmful volatile organic compounds (VOCs). Improved production speeds may also be enabled (e.g., up to 4000 feet per minute, up to 45.7 meters per minute, about, at least or at most 400 meters per minute, about, at least or at most 1200 meters per minute) compared to the conventional processes (e.g., -150 feet per minute for PVDF / NMP processes). In some embodiments, hundreds of feet of drying ovens in the traditional process can be greatly reduced (e.g., by tens of feet of curing zone), which significantly reduce the footprint. Compared to traditional processes (e.g., the PVDF / NMP electrode film fabrication process), the radiation curing process may enable up to 94% reduction in processing cost of electrode films, reduces the energy consumption (e.g., -151 MJ / kWh for NMP / PVDF processing to -27 MJ / kWh, an 82% reduction), and / or reduces greenhouse gas emission (e.g., -93 lbs CCh / kWh to -17 lbs CCh / kWh). Furthermore, energy storage devices made from such PFA-free, radiation curable electrodes would also be compliant against regulations targeting forever chemicals usage.

[0025] Another advantage of radiation (e.g., electron beam) curable binder materials is they can be initially utilized in the electrode film manufacturing process as monomers, short oligomer chains, and / or low molecular weight polymers that are then polymerized or crosslinked into higher molecular weight polymers when exposed to curing radiation (e.g., an electron beam). In addition, the crosslinked polymers formed after radiation (e.g., EB) exposure may display excellent substrate adhesion and mechanical robustness. Furthermore, the EB approach eliminates or reduces the use and / or problems associated with organic solvent usage (e.g., and toxic solvents) and PFA materials. Also, in some embodiments, EB slurries may contain high amounts of solids (e.g., >70 wt .% solids, compared to 50-60 wt% solids with an NMP -based slurry)), which is facilitated by the excellent wettability of the short EB polymer dispersions. The electron beam curing process may also be compatible with the formation of thick electrodes as the electrons used can easily penetrate opaque materials (e.g., with weight loadings of >25 mg / cm). As such,in some embodiments, successful energy electrode and energy storage devices are achieved when deploying aqueous-based EB polymer dispersions within existing battery electrode manufacturing infrastructure previously used to produce PVDF and NMP-based electrode coatings.

[0026] FIG. 1 shows the process for manufacturing a typical electrode using PVDFas a binder and NMP as a solvent. A cathode active material (CAM) is combined with a PVDFbinder, conductive additives and NMP solvent to form a slurry that is slurry cast onto an aluminum foil current collector to form an as-cast electrode. The as-cast electrode is heated to vaporize the NMP solvent to form the electrode and vaporized NMP, is known to be a toxic volatile organic compound (VOC) solvent.

[0027] In contrast, FIG. 2 shows the process of manufacturing an electrode utilizing a radiation curable binder. A CAM is combined with a radiation curable binder (i.e., RaiCure Monomer) and conductive additives, and the electrode fdm mixture is disposed (e.g., cast) over an aluminum foil current collector to form an as-cast electrode. In some embodiments, the electrode film mixture further comprises an aqueous solvent, and is slurry cast onto the aluminum foil cunent collector. The as-cast electrode is then radiation cured using electrons to crosslink the radiation curable binder to form a cured binder (i.e., crosslinked RaiCure Binder). As such, the process of FIG. 2 is contrasted with that of FIG. 1 in that toxic organic solvents are not used or off gassed in the process of forming the electrode.

[0028] The electrode film may comprise a cathode active material or an anode active material. In some embodiments, the electrode film and / or electrode film mixture comprises the active material in, in about, in at least, or in at least about, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%. 89 wt.%. 90 wt.%. 92 wt.%. 94 wt.%. 95 wt.%. 97 wt.%, 98 wt.% or 99 wt.%, or any range of values therebetween (e.g., 89-94 wt.%. 85-98 wt.%). In some embodiments, the active material is surface coated. In some embodiments, the surface coating is a high voltage surface coating (e.g., surface coated LCO). In some embodiments, the surface coating is an organic (e.g., polymer) coating, a metal coating, or combinations thereof. In some embodiments, the active material particles are coated with the coating at an amount (e g., solid coating amount) of, of about, of at least, or of at least about, 60 wt.%, 65 wt.%, 70 wt.%, 70.5 wt.%, 75 wt.%, 80 wt.% or 90 wt.%, or any range of values therebetween. In some embodiments, the active material includes a Dso particle size of, of about, of at most, or of at most about, 0. 1 pm, 0.5 pm, 1 pm, 2 pm. 3 pm, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 55 pm, 60 pm or 70pm. or any range of values therebetween. In some embodiments, the active material includes a Dio particle size of, of about, of at most, or of at most about. 0.1 pm, 0.5 pm, 1 pm, 2 pm, 3 pm, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 55 pm, 60 pm or 70 pm, or any range of values therebetween. In some embodiments, the active material includes a D90 particle size of, of about, of at most, or of at most about, 0.1 pm, 0.5 pm, 1 pm. 2 pm, 3 pm, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm. 45 pm. 50 pm. 55 pm. 60 pm or 70 pm. or any range of values therebetween.

[0029] The cathode active material can include, for example, carbon monofluoride (CFx), metal oxide, metal sulfide, or a lithium metal oxide. The lithium metal oxide can be, for example, a lithium nickel manganese cobalt oxide (NMC), a lithium manganese oxide (LMO), a lithium iron phosphate (LFP), a lithium cobalt oxide (LCO), lithium nickel manganese oxide (LNMO) and / or a lithium nickel cobalt aluminum oxide (NCA). In some embodiments, cathode active materials can comprise, for example, a layered transition metal oxide (such as LiCoCh (LCO), lithium nickel manganese oxide (LNMO), Li(NiMnCo)02 (NMC) and / or LiNio.8Coo.i5Alo.o502(NCA)), a spinel manganese oxide (such as LiMn2O4 (LMO) and / or LiMn1.5Nio.5O4 (LMNO)), an olivine (such as LiFePO4), chalcogenides (LiTiS2), tavorite (LiFeSO4F), aluminum, manganese oxide (MnOx), molybdenum oxide (MOO2), molybdenum disulfide (M0S2), nickel oxide (NiOx), or copper oxide (CuOx).

[0030] The anode active materials can include, for example, an insertion material (such as carbon, graphite (natural, artificial, synthetic or blends), hard or amorphous carbons and / or graphene), an alloying / dealloying material (such as silicon, silicon oxide, tin, and / or tin oxide), a metallic element, metal alloy or compound (such as Si-Al, and / or Si-Sn), and / or a conversion material (such as a titanate oxide (e.g., a lithium titanate (LTO)), manganese oxide, molybdenum oxide, nickel oxide, and / or copper oxide). The anode active materials can be used alone or mixed together to form multi-phase materials (such as Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si-SiOx-C, Sn- SnOx-C, Si-Sn-C, SiOx-SnOx-C, Si-SiOx-Sn. or Sn-SiOx-SnOx.).

[0031] In some embodiments, the electrode film and / or electrode film mixture can comprise a binder. In some embodiments, the electrode film comprises the binder in, in about, in at most, in at most about, 0.5 wt.%, 1 wt.%, 2 wt.%, 2.5 wt.%, 3 wt.%, 4 wt.%, 5 wt.%. 5.5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%. 15 wt.%, 20 wt.% or 25 wt.%, or any range of values therebetween (e.g., 2.5-5.5 wt.%). In some embodiments, the binder is a polymerizable binder. In some embodiments, the polymerizable binder is electronbeam ("e-beam" or “EB”) polymerizable and / or curable. In some embodiments, the EB curable binder is a short chain EB curable binder. In some embodiments, the EB curable binder (e.g., short chain EB curable binder) comprises a weight average molecular weight of, of about, of at least, or of at least about, 500 g / mol, 1,000 g / mol, 2,000 g / mol, 3,000 g / mol, 4,000 g / mol, 5,000 g / mol, 6,000 g / mol, 7,000 g / mol, 8,000 g / mol, 9,000 g / mol, 10,000 g / mol, 12,000 g / mol, 15,000 g / mol, 18,000 g / mol. 20,000 g / mol, 22.000 g / mol, 24.000 g / mol, 25,000 g / mol, 30,000 g / mol, 40,000 g / mol. 50,000 g / mol. 60.000 g / mol. 70,000 g / mol, 80,000 g / mol, 90,000 g / mol, 100,000 g / mol, 120,000 g / mol, 150,000 g / mol, 200,000 g / mol, 250,000 g / mol, 300,000 g / mol, 350,000 g / mol, 400,000 g / mol, 500,000 g / mol, 600,000 g / mol, 700,000 g / mol, 800,000 g / mol, 900,000 g / mol, 1,000,000 g / mol, 1,200,000 g / mol, 1,500,000 g / mol, 2.000,000 g / mol. 3,000,000 g / mol, 4,000.000 g / mol, 5,000,000 g / mol, 6,000,000 g / mol, 7,000,000 g / mol, 8,000,000 g / mol, 9,000,000 g / mol, 10,000,000 g / mol or 15,000,000 g / mol, or any range of values therebetween.

[0032] Binders may include an acrylated polyurethane resin (e g. Ucecoat 7689, Ucecoat 7510, and Ucecoat 7690 (i.e. a polyurethane acrylate, acrylate ester and / or acrylated monomer dispersion in water)), a hydroxy modified acrylated polyurethane resin (e.g., hydroxy modified Ucecoat 7690), an acrylate-methacrylate monomer blend (e g. Ebecryl 109), a monoacrylate of mono-ethoxylated phenol (e.g. Ebecryl 114), trimethylolpropane ethoxy triacrylate (TMPEOTA), an acrylonitrile and / or acrylamide (e.g., LA133), polytetrafluoroethylene (PTFE), a polyolefin, polyalkylenes, polyethers, styrene-butadiene, co-polymers of poly siloxanes, a poly siloxane, branched poly ethers, polyvinylethers, polyacrylic acid (PAA), styrene-butadiene rubber (SBR), co-polymers thereof, and / or admixtures thereof. The binder can include a cellulose, for example, carboxymethylcellulose (CMC). In some embodiments, the polyolefin can include polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), co-polymers thereof, and / or mixtures thereof. For example, the binder can include polyvinylene chloride, poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), poly(ethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block- poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxanecoalkylmethylsiloxane, co-polymers thereof, and / or admixtures thereof. In some embodiments, the binder may include an acrylated polyurethane resin, an acrylatemethacrylate monomer blend, a monoacrylate of mono-ethoxylated phenol, poly vinylidene fluoride (PVDF). and combinations thereof. In some embodiments, the binder may include an acrylated polyurethane resin, an acrylate-methacrylate monomer blend, a monoacrylateof mono-ethoxylated phenol, and combinations thereof. In some embodiments, the EB binder is selected from an acrylated polyurethane resin, a hydroxy modified acr laled polyurethane resin, an acrylate-methacrylate monomer blend, a monoacrylate of monoethoxylated phenol, trimethylolpropane ethoxy triacrylate, an acrylonitrile, an acrylamide, co-polymers thereof, and admixtures thereof

[0033] In some embodiments, the electrode film and / or electrode film mixture can comprise an additive. In some embodiments, the electrode film and / or electrode film mixture comprises the additive in, in about, in at most, in at most about, 0.05 wt.%, 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1 wt.%, 1.5 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 15 wt.%. 20 wt.% or 25 wt.%, or any range of values therebetween (e.g.. 3-5 wt.%, 1-5 wt.%). In some embodiments, the additive (e.g., conductive additive) includes a Dso particle size of, of about, of at most, or of at most about, 5 nm, 10 nm, 20 nm, 30 nm, 40 nm. 50 nm. 60 nm, 80 nm, 100 nm, 150 nm, 200 nm, 300 nm, 400 nm, 500 nm, 600 nm, 700 nm, 800 nm. 900 nm, 1 pm. 2 pm, 3 pm, 4 pm, 5 pm, 6 pm or 8 pm, or any range of values therebetween.

[0034] In some embodiments, the additive is a conductive additive, a rheological additive, an etching additive, or combinations thereof. In some embodiments, the additive is a conductive additive. In some embodiments, conductive additives may be selected from carbon black, carbon nano-particles, a graphitic material, graphite, graphenecontaining materials, hard carbon, soft carbon, carbon nanotubes, carbon nanofibers, porous carbon, conductive carbon, a high-aspect ratio conductive additive or a combination thereof. In some embodiments, the graphitic material can be a surface treated material. In some embodiments, the porous carbon can comprise activated carbon. In some embodiments, the porous carbon can comprise hierarchically structured carbon. In some embodiments, the porous carbon can include structured carbon nanotubes, structured carbon nanowires and / or structured carbon nanosheets. In some embodiments, the porous carbon can include graphene sheets. In some embodiments, the porous carbon can be a surface treated carbon. In some embodiments, the high-aspect ratio conductive additive is selected from a carbon nanofiber, a carbon nanotube, a chopped carbon nanofiber, a nanowire, a chopped metal thread, and combinations thereof. In some embodiments, the chopped metal thread comprises a metal nickel, copper, silver, and combinations thereof. The high aspect ratio fibers allow the battery electrodes to maintain electrical contact during the deformation. In some embodiments, the additive is a rheological additive. In someembodiments, a rheological additive includes oxalic acid. In some embodiments, the additive is an etching additive. In some embodiments, the etching additive is added to the electrode film mixture and / or to the current collector to remove or reduce the oxidation layer of a current collector once applied, thereby allowing the electrode film to strongly adhere to the current collector (e.g., resulting in improved electrical conductiv ity and battery performance). In some embodiments, an etching additive includes oxalic acid, nitric acid, HC1, or combinations thereof.

[0035] In some embodiments, the electrode film may comprise a surfactant. In some embodiments, the surfactant is selected from a hydrocarbon surfactant, a fluoro surfactant, a silicon surfactant, a polyoxypropylene surfactant, and combinations thereof. In some embodiments, the surfactant is selected from an amphiphilic surfactant, a cationic surfactant, an anionic surfactant, a non-ionic surfactant, a polymeric surfactant, a biosurfactant, and combinations thereof. In some embodiments, surfactants include polyethylene glycol derivatives (e g., Triton X-100) (molecular weight 695 g / mol to 1,000.000 g / mol)), polyvinylpyrrolidone (PVP), cationic poly(ethyleneimine) (PEI, molecular weight 10,000 g / mol to 1,000.000 g / mol), and anionic poly (acrylic acid) (PAA, molecular weight 15,000 g / mol to 1,000.000 g / mol). In some embodiments, surfactant provides properties such as reduced surface tension and energy, emulsification, dispersion and solubilization for casting and / or drying of the electrode film. In some embodiments, surfactants include structure-directing agents, carbon sources, porogen agents and stabilizer agents. In some embodiments, the surfactant includes a molecular weight of, of about, of at most, or of at most about, 300 g / mol, 500 g / mol, 600 g / mol, 700 g / mol, 800 g / mol, 1,000 g / mol, 2,000 g / mol, 5,000 g / mol, 10,000 g / mol, 15,000 g / mol, 20,000 g / mol. 30.000 g / mol, 40,000 g / mol, 50,000 g / mol. 60.000 g / mol or 80.000 g / mol, or any range of values therebetween. In some embodiments the electrode film and / or electrode film mixture comprises the surfactant in, in about, in at most, in at most about, 0.001 wt.%, 0.005 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, 0.06 wt.%, 0.07 wt.%, 0.08 wt.%, 0.09 wt.%, 0.1 wt.%. 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.% or 10 wt.%, or any range of values therebetween.

[0036] In some embodiments, the electrode film may comprise a thickener. In some embodiments, the thickener may be a cellulose, for example carboxymethylcellulose(CMC), or a salt form thereof, for example sodium-CMC. In some embodiments the electrode film and / or electrode film mixture comprises the thickener in, in about, in at most, in at most about, 0.001 wt.%, 0.005 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, 0.06 wt.%, 0.07 wt.%, 0.08 wt.%, 0.09 wt.%, 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.% or 10 wt.%, or any range of values therebetween (e.g.. 0. 1-0.8 wt.%).

[0037] The energy storage device can include an electrolyte. In some embodiments, the electrolyte can include a lithium source, such as a lithium salt, and a solvent, such as an organic solvent. In some embodiments, the electrolyte is a high voltage electrolyte. In some embodiment, the high voltage electrolyte is stable at voltages of, of about, of at least, or of at least about, 0.01 V, 0.1 V, 0.5 V, 0.8 V, 1 V, 1.5 V, 2 V, 2.5 V, 3 V, 3.5 V, 4 V, 4.1 V, 4.2 V, 4.3 V, 4.4 V, 4.5 V, 4.6 V, 4.7 V, 4.8 V or 5 V, or any range of values therebetw een.

[0038] In some embodiments, a lithium salt may be selected from lithium hexafluorophosphate (LiPFs), lithium tetrafluoroborate (LiBF4), lithium perchlorate (LiCICh), lithium bis(trifluoromethansulfonyl)imide (LiN(SChCF3)2), lithium trifluoromethansulfonate (LiSChCFs), lithium bis(pentafluoroethanesulfonyl)imide (C4FioLiN04S2), lithium bis(fluorosulfonyl)imide (F2LiNO4S2) (LiFSI), lithium bis(oxalato)borate (LiB(C2O4)2), lithium difluoro(oxalato) borate (LiBF2(C2O4), lithium difluorophosphate (F2LiChP), lithium oxalyldifluoroborate, lithium trifluorochloroborate (LiBFsCl), lithium hexafluoroarsenate (LiAsFe), lithium bis(trifluoromethanesulfonyl)imide (LiTFSi), combinations thereof, and / or the like. In some embodiments, the concentration of the lithium salt in the electrolyte is, is about, is at least, or is at least about, 0.5 M, 0.75 M, 1 M, 1.15 M, 1.25 M, 1.5 M, 1.75 M, 2 M, 5 M, 10 M, 15 M, 20 M, 21 M, 25 M or 30 M, or any range of values therebetween.

[0039] In some embodiments, an electrolyte solvent can include one or more ethers and / or esters. In some embodiments, an electrolyte solvent may be selected from ethylene carbonate (EC), dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), vinyl carbonate (VC), propylene carbonate (PC), fluoroethylene carbonate (FEC), 1,3-propane sultone (PS), tris(trimethylsilyl)borate (TMSB), and combinations thereof. In some embodiments, the electrolyte includes each electrolyte solvent and / or the total solvents in an amount of, of about, of at least, or of at least about, 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt% or 95 wt%, or any range of values therebetween. In some embodiments, the electrolyte includes each electrolyte solvent and / or the total solvents in an amount of, of about, of at least, or of at least about, 5 vol%, 10 vol%, 15 vol%, 20 vol%, 25 vol%, 30 vol%, 35 vol%, 40 vol%, 45 vol%, 50 vol%, 55 vol%, 60 vol%, 65 vol%, 70 vol%, 75 vol%, 80 vol%, 85 vol%, 90 vol% or 95 vol%, or any range of values therebetween.

[0040] In some embodiments, the electrolyte can further include an electrolyte additive. In some embodiments, the electrolyte additive may be selected from ethylene carbonate (EC), dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), vinyl carbonate (VC), propylene carbonate (PC), fluoroethylene carbonate (FEC), 1,3-propane sultone (PS), tris(trimethylsilyl)borate (TMSB). and combinations thereof. For example, in some embodiments the additive is VC, TMSB, and combinations thereof. In some embodiments, the electrolyte includes each electrolyte additive and / or the total electrolyte additives in an amount of, of about, of at least, or of at least about. 0.01 wt%, 0.05 wt%, 0.1 wt%, 0.2 wt%. 0.3 wt%. 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%. 0.8 wt%. 0.9 wt%. 1 wt%. 1.2 wt%. 1.5 wt%. 2 wt%. 2.5 wt%. 3 wt%. 3.5 wt%. 4 wt%, 4.5 wt%, 5 wt% or 6 wt%, or any range of values therebetween. In some embodiments, the electrolyte includes each electrolyte additive and / or the total electrolyte additives in an amount of, of about, of at least, or of at least about, 0.01 vol%, 0.05 vol%, 0. 1 vol%. 0.2 vol%, 0.3 vol%, 0.4 vol%, 0.5 vol%. 0.6 vol%, 0.7 vol%, 0.8 vol%, 0.9 vol%, 1 vol%, 1 .2 vol%, 1 .5 vol%, 2 vol%, 2.5 vol%, 3 vol%, 3.5 vol%, 4 vol%, 4.5 vol%, 5 vol% or 6 vol%, or any range of values therebetween.

[0041] Electrodes described herein may be prepared by various processes. As one example, in some embodiments an electrode film mixture (e.g. comprising the active material, binder, and optionally additives) are combined with a solvent to form an electrode film slurry. In some embodiments, the solvent is an aqueous solvent. As another example, in some embodiments an electrode film mixture (e.g. comprising the active material, binder, and optionally additives) is combined and an electrode film is formed in a solvent- free dry electrode manufacturing process. In some embodiments, the electrode film mixture further comprises a surfactant, thickener and / or an additive (e.g. a conductive additive, a rheological additive, and / or an etching agent). In some embodiments, the solvent includes water, an organic solvent, and combinations thereof. The electrode film slurry may then be cast upon a substrate to form an as-cast electrode film. In some embodiments, casting of the electrode film slurry may be performed using a doctor blade,spray coating, comma bar, slot die, aerosol, gravure, screen printing, imprinting, spincoating, electrospinning, ultrasonic spray, electrostatic spray, and combinations thereof. The as-cast electrode film may then be dried and / or cured to form an electrode film. In some embodiments, the as-cast electrode film or electrode film is calendered (e.g. a roll- to-roll process). In some embodiments, the as-cast electrode film or electrode film is not calendered. In solvent-free dry electrode manufacturing processes the electrode film may be formed using dry materials, such as a calendering process. In some embodiments, the substrate which the dry electrode film or electrode film slurry is cast upon is a current collector, and as such an electrode is formed once the electrode film is deposited, dried and / or cured. In some embodiments, the electrode film (e.g., EB cured electrode film) has an adhesion strength to the current collector of, of about, of at least, or of at least about, 0.05 N / cm, 0.1 N / cm, 0.2 N / cm, 0.5 N / cm, 1 N / cm, 2 N / cm, 3 N / cm, 3 N / cm, 4 N / cm, 5 N / cm, 6 N / cm, 7 N / cm, 8 N / cm, 9 N / cm, 10 N / cm, 12 N / cm, 15 N / cm, 20 N / cm, 25 N / cm or 30 N / cm, or any range of values therebetween.

[0042] In some embodiments, the electrode film slurry includes a solids content of, of about, of at least, or of at least about 50 wt.%. 60 wt.%. 65 wt.%. 70 wt.%. 75 wt.%. 80 wt.%, 85 wt .%, 90 wt.% or 95 wt.%, or any range of values therebetween. In some embodiments, the electrode film slurry' includes a viscosity' of, of about, of at least, or of at least about. 300 cP, 400 cP, 500 cP. 600 cP, 800 cP, 1,000 cP, 1,500 cP, 2,000 cP, 2,500 cP, 3.000 cP. 3,500 cP, 4,000 cP, 4,500 cP, 5.000 cP. 6,000 cP. 7,000 cP, 8,000 cP, 9.000 cP, 10,000 cP, 12,000 cP, 15,000 cP, 20,000 cP, 25,000 cP, 30,000 cP, 35,000 cP, 40,000 cP, 45,000 cP, 50,000 cP or 55,000 cP, or any range of values therebetween.

[0043] In some embodiments, a solvent (e.g., an organic solvent) and a binder (e.g., EB curable binder. PVDF) are combined to form a first mixture, the first mixture is combined with a conductive additive to form a second mixture, and an active material is combined with the second mixture to form an electrode film slurry.

[0044] In some embodiments, a solvent (e.g., water) and a binder (e.g., EB curable binder) are combined to form a first mixture, the first mixture is combined with a first amount of an active material (e.g., cathode active material) to form a second mixture, and the second mixture is combined with a second amount of the active material to form the electrode film slurry. In some embodiments, a solvent and a binder (e.g., EB curable binder) are combined to form a first mixture, the first mixture is combined with a first amount of an active material (e.g., cathode active material) and a conductive additive to form a second mixture, and the second mixture is combined with a second amount of theactive material to form the electrode film slurty. In some embodiments, the process by which the electrode film slurry is formed enables a desired solids content to be achieved. In some embodiments, a solvent and a binder (e.g., EB curable binder) are combined to form a first mixture, the first mixture is combined with a first amount of an active material (e.g., cathode active material) to form a second mixture, the second mixture is combined with a conductive additive to form a third mixture, and the third mixture is combined with a second amount of the active material to form the electrode film slurry.

[0045] In some embodiments, the amount of the first active material out of the total amount of active material is, is about, is at most, or is at most about, 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 35 wt.%, 40 wt.%, 45 wt.% or 50 wt.%, or any range of values therebetween. In some embodiments, the amount of the second active material out of the total amount of active material is, is about, is at least, or is at lease about, 50 wt.%, 55 wt.%, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.% or 90 wt.%, or any range of values therebetween.

[0046] In some embodiments, the second mixture is mixed (e.g., high shear mixed). In some embodiments, the mixing (e.g., high shear mixing) of the second mixture reduces a size (D50 size) of particles (e.g., active material, binder and / or additive, such as a conductive additive) within the second mixture. In some embodiments, a particle (e.g., active material, binder and / or additive, such as a conductive additive) within the mixed (e.g., high shear mixed) second mixture includes aDso particle size of, of about, of at most, or of at most about, 5 nm, 10 nm, 20 nm, 30 nm, 40 nm, 50 nm, 60 nm, 80 nm, 100 nm, 150 nm, 200 nm, 300 nm, 400 nm, 500 nm, 600 nm, 700 nm, 800 nm, 900 nm, 1 pm, 2 pm, 3 pm, 4 pm, 5 pm, 6 pm or 8 pm, or any range of values therebetween.

[0047] Drying may be performed by heating (e.g., vacuum heating and / or convection heating) the as-cast electrode film to evaporate the solvent. Curing may be performed to polymerize the binder to form a binder matrix within the electrode film. In some embodiments, curing is performed by an energy source, such as for example photons and / or electrons. In some embodiments, curing is performed by an electron beam (“e- beam” or “EB’ ). In some embodiments, the curing is performed with an EB with, with about, with at least, or with at least about, 50 kV, 100 kV, 150 kV, 200 kV, 250 kV 300 kV, or any range of values therebetween. In some embodiments, the curing is performed with an EB with, with about, with at least, or with at least about, 5 kGy. 10 kGy, 15 kGy, 20 kGy, 25 kGy, 30 kGy, 40 kGy, 50 kGy, 60 kGy, 70 kGy. 80 kGy or 100 kGy, 200 kGy, 300 kGy, 400 kGy, 500 kGy, 600 kGy or any range of values therebetween.

[0048] An energy storage device may be formed by disposing a cathode, anode, separator and electrolyte within a housing, wherein the separator is positioned between the cathode and anode. The energy storage device may be in the form of a jellyroll. FIG. 3 shows a jellyroll energy storage device with a cathode electrode formed a radiation cured binder and with an LCO active material, an anode with a graphite active material, and a separator disposed therebetween. The cathode, anode and separator stack are rolled into a jellyroll, and positioned within a housing along with a high voltage stable electrolyte, and then sealed with a cap to form the energy storage device. A solid electrolyte interface (SEI) for a cathode (i.e., cathode electrolyte interface (CEI)) formed with the aid of solvents and / or additives (e.g., TMSB) within the electrolyte, and may prevent further reaction of the electrolyte with the cathode surface.

[0049] The energy storage device may be operated at an operating voltage. In some embodiments, the operating voltage is a high operating voltage. In some embodiments, the high operating voltage is a voltage of, of about, of at least, or of at least about, 4 V. 4.1 V, 4.2 V, 4.3 V, 4.4 V, 4.5 V, 4.6 V, 4.7 V. 4.8 V or 5 V, or any range of values therebetween. In some embodiments, the energy storage device may operate at a high voltage for or for about 500 cycles with a specific capacity retention of, of about, of at least, or of at least about, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99%, or any range of values therebetween. In some embodiments, the energy storage device may operate at a high voltage for or for about 1000 cycles with a specific capacity retention of, of about, of at least, or of at least about, 80%, 81 %, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99%, or any range of values therebetween.EXAMPLESExample 1

[0050] A high voltage battery utilizing a radiation cured cathode (i.e., EB Binder” of FIG. 4B) was formed and compared to an energy storage device utilizing a traditional cathode (i.e., “PVDF” of FIG. 4A). The EB Binder cathode was formed from an electrode mixture including solids at: high voltage coated LCO 89-94 wt.%, conductive Additive 3-5 wt.%, polyurethane acry late radiation curable binder 2.5-5.5 wt.%, and sodium CMC thickener 0.5%. The solid electrode mixture was mixed with water, deposited onto a current collector, and EB cured to form the cathode electrode.

[0051] The PVDF cathode was formed from an electrode mixture including solids at: high voltage coated LCO 89-94 wt.%, Conductive Additive 3-5 wt.%, PVDF 2.5- 5.5 wt.%, and sodium CMC thickener 0.5%. The solid electrode mixture was mixed with NMP, deposited onto a current collector, and heated to form the cathode electrode.

[0052] The EB Binder and PVDF cathodes were used to form batteries with the same form factors including a graphite anode and a separator positioned therebetween, and a high voltage electrolyte of 1.15M LiPF6 EC / DMC / DEC (3:4:3) v% + 1 v% VC + 0.5 v% TMSB was added into the housing.

[0053] FIGS. 4 A and 4B shows cycling data of pouch cells created with a high- voltage LCO cathode against a graphite anode, wherein FIG. 4A contains a PVDF cathode and the FIG. 4B an EB-produced cathode, and shows the performance comparison between the PVDF and EB Binder batteries, respectively, based on the specific capacity as a function of cycle number. Cycling comparison between pouch cell batteries produced with a high-voltage LCO cathode that utilizes PVDF vs. one that utilizes EB binders. Batteries were cycled between 3.0 and 4.4V. The data presented is an average of a batch of batteries for each cell type. The cells were cycled at a 1C charge and discharge current (blue) over -1,000 cycles in the voltage window between 3.0 and 4.4V, with state of health checks at lower discharge currents every 50 and 100 cycles (other rates indicated by colors, see legend). The pale blue border in the plot indicates the standard deviation across the batch of cells for the specific capacity obtained at 1C for each cycle.

[0054] Both the EB Binder and PVDF batteries showed similar raw capacities. The batteries were cycled in the voltage window from 3.0V to 4.4V throughout their charge and discharge cycling routine. As seen in FIG. 4B, the EB Binder battery shows improved specific capacity retention at and beyond 550 high voltage cycles. It is observed that in the first -150 cycles the rate capability of the PVDF-based batteries is up to 10 mAh / g greater for the 1C charge rate (blue); however, after this early difference, the retention of the EB- produced batteries is superior throughout the rest of the cycling. The PVDF-based batteries cross the 80% capacity retention threshold at approximately 900 cycles (1C charge rate) whereas the EB-produced batteries remain above that threshold for 1100 total cycles. The EB-produced batteries also demonstrated improved consistency compared to their PVDF- based counterparts. For example, at 1100 cycles, the standard deviation of the PVDF-based cells is ±11.48 mAh / g whilst the standard deviation of the EB-produced cells is only ±5.8 mAh / g. Furthermore, the EB Binder cathode demonstrated enhanced electrode substrate adhesion (3x increase) and a 15-20% increase in energy density over the PVDF cathode.Overall, the EB binders display similar electrochemical performance to the incumbent PVDF counterpart while displaying superior substrate adhesion for enhanced post processing.Example 2

[0055] FIG. 5A shows voltage vs. specific capacity results and FIG. 5B shows the cyclic voltammetry current vs. voltage results of experiments performed using energy storage device half coin cells using a PVDF based LCO electrode compared to a radiation cured LCO electrode. The half coin cells were charged and discharged at a rate C / 5. The cyclic voltammetry measurements of FIG. 5B were performed between 2.8-4.45V at a sweep rate of 0.05 mV / s. FIGS. 5A and 5B demonstrate the stability of the EB binder over the full range of voltages applicable to the active material, displaying similar qualities to the PVDF based binder system, with no evidence of spikes or jumps that would indicate unwanted side reactions occurring due to the presence of the EB binder.

[0056] While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.

[0057] Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0058] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a singleimplementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.

[0059] Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and / or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. For example, any of the components for an energy storage system described herein can be provided separately, or integrated together (e.g., packaged together, or attached together) to form an energy storage system.

[0060] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0061] Conditional language, such as “can.” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodimentsdo not include, certain features, elements, and / or steps. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and / or steps are included or are to be performed in any particular embodiment.

[0062] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0063] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of. within less than 0.1% of, and within less than 0.01% of the stated amount, depending on the desired function or desired result.

[0064] The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.

[0065] The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

Claims

WHAT IS CLAIMED IS:

1. An electrode film, comprising: an active material: a binder consisting essentially of an electron beam (EB) cured binder; and a conductive additive.

2. The electrode film of Claim 1, wherein the electrode film is substantially free of a perfluoroalkyl and polyfluoroalkyl (PFA).

3. The electrode film of Claim 1 or 2, wherein the active material is a cathode active material.

4. The electrode film of Claim 3, wherein the cathode active material is selected from manganese dioxide, lithium iron phosphate (LFP), lithium cobalt oxide (LCO), lithium nickel manganese oxide (LNMO), nickel manganese cobalt oxide (NMC), nickel cobalt aluminum oxide (NCA), lithium manganese iron phosphate (LMFP), and combinations thereof.

5. The electrode film of Claim 4, wherein the cathode active material is LCO, LNMO, and combinations thereof.

6. The electrode film of any one of Claims 1-5, wherein the EB cured binder is selected from an acrylated polyurethane resin, a hydroxy modified acrylated polyurethane resin, an acrylate-methacrylate monomer blend, a monoacrylate of monoethoxylated phenol, trimethylolpropane ethoxy triacrylate, an acrylonitrile, an acrylamide, co-polymers thereof, and admixtures thereof.

7. The electrode film of any one of Claims 1-6, wherein the active material comprises an active material particle size of about 1 pm to about 50 pm.

8. The electrode film of any one of Claims 1-6, wherein the conductive additive comprises a conductive additive particle size of about 10 nm to about 5 pm.

9. The electrode film of any one of Claims 1-8, further comprising a surfactant.

10. An electrode, comprising: a current collector; and the electrode film of any one of Claims 1-9 disposed over the current collector.

11. The electrode of Claim 10, where an adhesion strength of the electrode film to the current collector is about 0.1 N / cm to 10 N / cm.

12. An energy storage device, comprising: the electrode of Claim 10 or 11;a second electrode; a separator disposed between the electrode and the second electrode; an electrolyte; and a housing, wherein the electrode, second electrode, separator and electrolyte are disposed within the housing.

13. A method of preparing an electrode film, comprising: combining solvent and an electron beam (EB) curable binder to form a first mixture; combining a first amount of an active material with the first mixture to form a second mixture; combining a second amount of the active material with the second mixture to form an electrode film slurry; and exposing the electrode film slurry to an electron beam to form an electrode film.

14. The method of Claim 13, further comprising combining a conductive additive with the second mixture prior to combining a second amount of the active material with the second mixture.

15. The method of Claim 13, wherein the first amount of an active material is combined with a conductive additive and the first mixture to form the second mixture.

16. The method of any one of Claims 13-15, wherein the electrode film slurry comprises a solids content of at least about 60 wl.%.

17. The method of any one of Claims 13-16, wherein the EB curable binder is short chain EB curable binder.

18. The method of any one of Claims 13-17, further comprising high shear mixing the second mixture.

19. The method of any one of Claims 13-18, wherein the electrode film slurry comprises a viscosity of about 500 cP to about 50,000 cP.

20. A method of forming an electrode, comprising: performing the method of any one of Claims 13-19; and depositing the electrode film mixture over the current collector prior to exposing the electrode film slurry to an electron beam.

21. A method forming an energy storage device, comprising: performing the method of Claim 20; anddisposing the electrode, a second electrode, a separator and an electrolyte within a housing, wherein the separator is disposed between the electrode and the second electrode.

Images