Electrode recycling

Abstract

A method of separating an electrode for recycling, the electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the method comprising treating the electrode with a solvent, delaminating the active material layer from the electrode to form a metal component and an active material component, collecting the metal component, and collecting the active material component.

Description

[0001] IRL01-134265PC

[0002] Electrode Recycling

[0003] FIELD

[0004] The present description relates to methods of separating electrode materials for recycling. The described methods are directed to battery processing without shredding.

[0005] BACKGROUND

[0006] Battery manufacturing is environmentally costly in terms of material and energy usage.

[0007] Direct recycling of batteries is the recovery, regeneration, and reuse of battery components without breaking down the chemical structure. The direct recycling of battery material enables significant savings in greenhouse gas emissions, the time to process materials, and cost. There are increased incentives to move towards circular and sustainable resource consumption, in view of climate change and resource scarcity.

[0008] There is a need to improve the processes used to recover battery materials. Present methods of battery recycling often involve shredding, the mechanical cutting of bulk into smaller parts, which results in the mixing of battery components. Battery shredding causes up to about 30% of the total material to be lost, i.e. not recovered for reuse. The use of shredding in battery recycling processes delivers low purity products and subsequent purification of the products is required. Commonly used purification methods involve hydrometallurgy, for example leaching with strong acids. The disposal of leaching acids and byproducts presents an environmental hazard. There is a need for a battery recycling method that produces high purity products, particularly at a sufficient purity level to avoid the use of further refinement. There is a need for a battery recycling method with a higher yield and lower material loss.

[0009] The present invention seeks to alleviate one or more of the problems detailed herein.

[0010] SUMMARY OF THE INVENTION

[0011] In a first aspect, there is provided a method of separating an electrode for recycling, the electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the method comprising: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

[0012] In a second aspect there is provided a method of producing an electrode for a cell, the method comprising: i) providing an active material component produced according to the first aspect; ii) mixing the active material component with a binder and solvent to form a slurry; iii) coating a metal layer with the slurry to form a coated metal; iv) drying the coated metal to form an electrode.

[0013] In a third aspect there is provided a method of producing a cell comprising assembling the electrode produced by the method of the second aspect into a cell.

[0014] In a fourth aspect there is provided a recycling process comprising a method of disassembling a cell to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the recycling process comprising preparing the electrode for separation by removing the electrode from a cell and: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

[0015] In a fifth aspect there is provided a process of recycling and reusing components of a cell by disassembling a cell to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the recycling process comprising preparing the electrode for separation by removing the electrode from a cell and: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component. e) heating the active material component to form isolated active material; f) mixing the isolated active material, a second binder and a solvent to form a slurry; g) coating a metal film with the slurry to form a coated metal; h) drying the coated metal to form a new electrode.

[0016] In a sixth aspect there is provided an electrode obtainable by the method of the second aspect or obtainable by the process of the fifth aspect.

[0017] In a seventh aspect there is provided a cell obtainable by the process of the fifth aspect, wherein the fifth aspect further comprises the step of assembling the new electrode into a cell.

[0018] In a further aspect there is provided a method of separating an electrode for recycling, the electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the method comprising: a) treating the electrode with a solvent; b) removing the active material layer from the electrode by physical means to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

[0019] DESCRIPTION OF THE DRAWINGS

[0020] The present invention will now be described by way of example with reference to the accompanying drawings. In the drawings:

[0021] Figure 1 shows an example of solvent bath setup for electrode delamination and material collection.

[0022] Figure 2 shows a cross sectional view an electrode.

[0023] Figure 3 shows an example of a conveyor arrangement.

[0024] Figure 4 shows a detailed view of an example of an electrode passing through a conveyor arrangement.

[0025] Figure 5 shows a top-down view of an example of a multi-strand conveyor arrangement. Figure 6 shows an alternate conveyor arrangement.

[0026] Figure 7 shows SEM images of graphite. Figure 7a shows virgin graphite. Figure 7b shows graphite separated from an electrode.

[0027] DETAILED DESCRIPTION

[0028] The following description is presented to enable any person skilled in the art to make and use the invention and is provided in the context of a particular application. Various modifications to the disclosed embodiments will be apparent to those skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the present invention. Embodiments are described by way of example only.

[0029] In an aspect there is provided a method of separating an electrode for recycling, the electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the method comprising: a) treating the electrode with a solvent; b) removing the active material layer from the electrode by physical means to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

[0030] Preferably, the metal layer delaminates from the active material layer. The metal layer may be removed from the electrode substantially intact as a single piece. The active material preferably delaminates and is separated from the electrode in a single piece. Preferably at least about 80 wt% of the active material layer delaminates as a single piece, more preferably at least about 90 wt% of the active material layer delaminates as a single piece, more preferably at least about 95 wt% of the active material layer delaminates as a single piece, preferably substantially all the active material layer delaminates as a single piece. Preferably the active material layer is not removed in small pieces, preferably a smallest piece of the active material removed from the electrode is greater than about 1 cm2, preferably greater than about 2 cm2. Preferably the metal layer delaminates and is separated from the electrode as a single piece. Preferably at least about 80 wt% of the metal layer delaminates as a single piece, more preferably at least about 90 wt% of the metal layer delaminates as a single piece, more preferably at least about 95 wt% of the metal layer delaminates as a single piece Without being bound by theory, it is thought that the delamination of electrode layers is achieved by a hydrostatic effect of the solvent.

[0031] Physical means may not be required to separate layers of the electrode as the action of the solvent alone may cause the delamination of the electrode to form a metal component and an active material component. Optionally, physical means may be used in combination with the steps of the method described herein. In an example, abrasion of the active material layer may be used to delaminate the metal layer from the active material layer.

[0032] The method of separating an electrode for recycling is highly advantageous as compared to known methods, particularly in maximising the yield of collected material, the method being applicable to both anodes and cathodes. The method is further advantageous in terms of minimising energy usage, minimising hazardous chemical usage, and minimising carbon emissions.

[0033] The methods described herein solve the problems identified in the background section. The method of separation does not require battery shredding; thus, the waste streams of different materials are kept separate and therefore the purity of collected products is higher than methods involving shredding. The method converts battery waste into market grade active materials for reuse in batteries.

[0034] The solvent preferably comprises acetone, acetyl triethyl citrate (ATEC), butyrolactone (GBL), cyclohexanone, cyclopentanone, dibutyl phthalate, dibutyl sebacate, dibutyl carbonate, dibutyl phthalate, dihydrolevoglucosenone, dimethylacetamide, N,N-dimethylformamide, dimethylsulfoxide, 1 ,4-Dioxane, 3-Heptanone, hexamethyl phosphoramide, 3-Heptanone, methyl ethyl ketone, N-methyl-2-pyrrolidone, 3-octanone, 3-pentanone, propylene carbonate, tetra hydrofuran, tetramethylurea, triacetin, triethyl citrate, triethyl phosphate, trimethyl phosphate, N,N tetrabutylsuccindiamide, alkali water, an alcohol, formamide, 1 ,4-Dioxane, 0.2 M aqueous hydrochloric acid (HCI) or a combination of two or more thereof.

[0035] The solvent preferably comprises water, methyl ethyl ketone (MEK), N-Methyl-2-pyrrolidone (NMP), tetra hydrofuran (THF), chloroform, xylene, toluene, acetone, or a combination of two or more thereof, preferably water, preferably distilled water and / or deionised water. Advantageously, the process of separating electrode materials can be carried out in non-toxic and readily available solvents, such as water. The method can advantageously be carried out at room temperature, meaning that no energy is required to heat the solvent. The solvent may conveniently be reused to process multiple electrodes. A mixture of one or more solvents may be used. The concentration of a solvent diluted in water is preferably greater than 50%, preferably greater than 60%, preferably greater than 70%.

[0036] The solvent is preferably a polar solvent, preferably wherein the polar solvent has a polarity of greater than about 0.5, measured relative to the polarity of water, where the polarity of water is 1.

[0037] The solvent preferably comprises water and / or an organic solvent, preferably water. The use of water as the solvent is advantageous for example because it is readily available and nontoxic.

[0038] The solvent may be selected in dependence on the binder of the electrode to be processed. For example, for a styrene-butadiene rubber / carboxymethyl cellulose (SBR / CMC) binder, the solvent is preferably water. Effective delamination, meaning release of one layer from another layer, is achieved by selecting an appropriate solvent for the binder.

[0039] The methods and systems described herein are advantageously effective at separating cured binder. Binder may be cured by drying during electrode manufacture. In a manufacturing environment it is common that cells which have been assembled but not yet cycled, such as those having a fault, are wasted. The method of delamination and material recovery is effective for separating a metal layer, an active material and a cured binder.

[0040] Preferably the method does not comprise the use of acid. It is known to dissolve the metal of an electrode using acid; this does not permit the collection and reuse of metal. Preferably the method does not comprise the use of an acid with a pH of less than about 3. Preferably the pH of the solvent is greater than about 3, preferably greater than about 5, preferably greater than about 6, preferably the solvent has a pH of about 7. It is an advantage of the invention that use of an acid is not needed in the recycling process. Use of an acid can damage the structure of an electrode component and therefore the recycling process is improved by not needing to use an acid. Further, such a process without acid is more environmentally friendly.

[0041] With reference to figure 1 , the method of separating an electrode will be described by way of example. An apparatus 100 is shown, a solvent bath 101 is provided with a conveyor 102 at least partially submerged in a solvent 108. The solvent bath 101 has a sloped base 106. An electrode 103 is conveyed by the conveyor 102 into the solvent. The electrode 103 comprises a metal layer and an active material layer. The electrode is treated by the solvent by being in contact with the solvent. The active material layer is removed from the electrode 103 to leave a metal component 105. In this example, the metal component 105 is liberated from the active material layer of the electrode and remains on the surface of the conveyor 102. The metal component 105 is conveyed out of the solvent bath for collection. The active material layer comprises an active material and a binder. In this example, it is believed that the binder swells in the solvent and the active material separates from the metal component. The active material component 104 sinks to a lowest point of the sloped base of the solvent bath. The active material component may be collected from the bath, for example via an openable channel 107.

[0042] Figure 2 shows a schematic of a cross section of an electrode 200. The electrode 200 has a metal layer 201 and an active material layer 202. When assembled as a cell, the metal layer of the electrode functions as a conductor and is a current collector in the cell. The active material layer 202 comprises a binder and an active material component. The active material component may be or may further comprise a conductive agent. In the electrode shown in figure 2, the metal layer is substantially thinner than the active material layer. Preferably, the metal layer has a thickness in the range of about 1 pm to about 100 pm, preferably about 2 pm to about 20 pm. Preferably, the active material layer has a thickness of about 10 pm to about 1 mm, preferably about 50 pm to about 500 pm.

[0043] Preferably the binder is distributed throughout the active material layer 202. The binder may preferably be distributed substantially homogeneously throughout the active material layer. Preferably the binder is not a distinct layer between the metal layer and active material layer. The binder may, at least to some extent, have aggregated at the interface between the metal layer and the active material layer. Without being bound by theory, it is thought that the binder swells when treated with solvent, thereby expanding and causing the metal layer to separate from the active material layer.

[0044] The binder preferably comprises carboxymethyl cellulose (CMC), styrene-butadiene rubber (SBR), polyacrylic acid (PAA), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), or a combination of two or more thereof, preferably styrene-butadiene rubber I carboxymethyl cellulose (SBR / CMC), PVDF or a combination of two or more thereof. Conveniently, CMC and SBR are often used in combination and are found in electrodes. SBR / CMC is commonly used with cathodes comprising LiFePC . PAA is commonly used with anodes comprising silicon. Lithium sulfur cells and sodium ion cells may comprise a PVDF binder. PVDF and PTFE may be used in anodes and cathodes. PVDF and / or PTFE is commonly used with nickel manganese cobalt (NMC) cathodes and nickel cobalt aluminium (NCA) cathodes. Preferably, the binder comprises SBR / CMC and the solvent comprises water, ethanol, acetone, MEK, or a combination of two or more thereof, preferably water. Such solvents are particularly suitable for use with the binder.

[0045] Preferably, the binder comprises PAA, and the solvent comprises water. Such solvents are particularly suitable for use with the binder.

[0046] Preferably, the binder comprises PVDF, and the solvent comprises N-Methyl-2-pyrrolidone (NMP), methyl ethyl ketone (MEK), N,N-dimethylformamide, Dimethylsulfoxide, propylene carbonate, tetra hydrofuran, or a combination of two or more thereof, preferably NMP or MEK, preferably NMP. Such solvents are particularly suitable for use with the PVDF binder.

[0047] Preferably, the binder comprises PTFE and the solvent comprises NMP, MEK, N,N- dimethylformamide, Dimethylsulfoxide, propylene carbonate, tetra hydrofuran, or a combination of two or more thereof, preferably NMP or MEK, preferably NMP. Such solvents are particularly suitable for use with the PTFE binder.

[0048] The metal layer preferably comprises copper, iron, aluminium, magnesium, zinc, nickel, or a combination of two or more thereof, preferably copper or aluminium. The metal(s) in an electrode are typically selected in dependence on their galvanic potential, with aluminium being preferred as a cathode material and copper being preferred as an anode material. The method of separation is advantageously applicable to all metals commonly used in batteries.

[0049] The active material layer preferably comprises graphite, silicon, carbon black, sodium, lithium, iron, phosphorous, nickel, cobalt, manganese, niobium, or a combination of two or more thereof. The active material preferably comprises lithium iron phosphate and / or lithium manganese iron phosphate.

[0050] The electrode is preferably an anode. When the electrode is an anode, the metal layer preferably comprises copper, the active material preferably comprises graphite, the binder preferably comprises SBR / CMC, and the solvent preferably comprises water. Advantageously in this system, the delamination of copper from the active material layer is achieved using only water.

[0051] The electrode is preferably a cathode. In an example where the electrode is a cathode, the metal layer preferably comprises aluminium, the active material preferably comprises nickel and the binder preferably comprises polyvinylidene fluoride (PVDF) and / or polytetrafluoroethylene (PTFE), and the solvent preferably comprises N-Methyl-2-pyrrolidone (NMP).

[0052] In another example, the metal layer preferably comprises aluminium, the active material preferably comprises lithium iron phosphate or lithium manganese iron phosphate, the binder comprises SBR / CMC and the solvent preferably comprises water. Advantageously in this system, the delamination of aluminium from the active material layer is achieved using only water.

[0053] The step of removing the active material layer is preferably performed by abrading the active material layer. Abrading the active material layer is preferably performed by at least one of: a brush, preferably roller brushes, a scraper tool, a blade, a bar, a solvent jet, or an air jet. Advantageously, the active material layer can be fully removed from the electrode using simple processing. Advantageously, froth floatation is not required. Advantageously, the use of an acid is not required.

[0054] The metal layer may delaminate from the active material layer by the electrode being treated by a solvent. Preferably the electrode is submerged in the solvent, preferably for a duration of about 3 minutes to about 2 hours, preferably for a duration of about 5 minutes to about 1 hour, preferably for a duration of about 5 minutes to about 15 minutes. The duration that the electrode is in the solvent may be referred to as the residence time. The residence time is preferably selected as a balance of sufficiently fast throughput of electrodes and adequate time in the solvent for delamination of the layers to occur.

[0055] The active material component may be purified by extended exposure to the solvent, for example the active material may be in the solvent for about 5 minutes to about 15 minutes. For example, the active material in the active material layer of the electrode may have impurities introduced by the manufacture of the material. For example, active material comprising graphite may have sulfur impurities; active material comprising nickel manganese cobalt (NMC) may have sulfur and / or sodium impurities; active material comprising lithium iron phosphate (LFP) may have sulfur and / or sodium and / or fluorine impurities. Precise material purity is required for battery manufacture, thus it is advantageous to achieve purification and separation of electrode materials in a single process.

[0056] Preferably the solvent is at a temperature of about 10°C to about 60°C, preferably about 15°C to about 40°C, preferably about 18°C to about 25°C. In an example where the method is carried out using a conveyor, the action of the conveyor may warm the solvent above ambient temperature. Preferably no separate heating of the solvent is performed.

[0057] The removal of the active material layer preferably comprises passing the electrode through roller brushes disposed above and / or below the active material layer. The roller brushes preferably rotate about an axis parallel to a surface plane of the electrode, rotation of the brushes may preferably occur in contact with the surface plane of the electrode.

[0058] The removal of the active material layer from the electrode may preferably be aided by the use of rollers arranged on opposing sides of the electrode. The electrode passes through the set of rollers and may preferably be compressed between the opposed rollers, see for example the arrangement shown in figure 3.

[0059] The step of collecting the active material component preferably comprises removing the active material component from the solvent, preferably by filtration, centrifugation, drying, or a combination of two or more thereof. The active material component may preferably be collected from the solvent bath, for example by draining the solvent from the bath.

[0060] Removing the active material component preferably comprises drying the active material component removed from the solvent. Preferably the drying is between about 40°C to about 450°C, preferably about 100°C to about 300 °C, and / or wherein the drying is performed for about 30 minutes to about 8 hours, preferably about 1 hour to about 4 hours. Drying at elevated temperature may cause binder remaining in the active material component to degrade, for example the binder may burn off.

[0061] The drying is preferably performed at around room temperature to around 70°C under a pressure less than atmospheric pressure. The active material component is preferably vacuum dried, preferably at around 60°C.

[0062] The method is preferably performed in a solvent bath. The solvent bath preferably has a sloped base with a higher end and a lower end disposed at opposing sides of the sloped base. The solvent bath preferably has a sloped base having a lowest point, as shown in figure 1. The active material component can be collected from a lowest portion of the sloped base.

[0063] The method may comprise a post-processing treatment to recover the active material from the active material layer. The post-processing treatment comprises treating the active material layer with a second solvent to separate the active material component from the binder. The second solvent for treatment may be selected in dependence on the binder. Preferably the solvent comprises water, methyl ethyl ketone (MEK), N-Methyl-2-pyrrolidone (NMP), tetra hydrofuran (THF), chloroform, xylene, toluene, acetone, or a combination of two or more thereof, preferably water, preferably distilled water and / or deionised water.

[0064] Step a) of the method preferably comprises immersing the electrode in a solvent, preferably the solvent is provided in a solvent bath.

[0065] Step c) of the method preferably comprises removing the active material layer from the electrode in a solvent bath. The metal layer may be liberated from the electrode and float on the surface of the solvent. Preferably, the metal layer is conveyed by rollers out of the solvent bath.

[0066] The proportion of surface area of the electrode that is exposed to the solvent is preferably above about 50%, preferably above about 80%, more preferably above about 90%, more preferably above about 95%. Exposure of a high proportion of the surface of the electrode means that the solvent is in contact with a majority of the surface of the electrode.

[0067] The method preferably further comprises the electrode being conveyed into the solvent bath on a conveyor belt, preferably a perforated conveyor belt, a gridded conveyor belt or an O- ring conveyor. An O-ring conveyor is preferably arranged with multiple strands which are moved by rotation of rollers. An advantage of a perforated, gridded and O-ring conveyors is that they allow solvent to be in contact with the bottom surface of the electrode. Further, an O-ring conveyor allows the electrode to be supported on the strands and further allows solvent to be in contact with the bottom surface of the electrode.

[0068] The conveyor belt preferably comprises an angled portion for conveying the electrode into the solvent bath. The angled portion of the conveyor belt preferably conveys the electrode from a higher region outside of the solvent bath into a lower region in the solvent bath. This is shown in figure 1 , the conveyor belt 102 descends from a higher region into the solvent bath 101.

[0069] The conveyor belt preferably comprises an angled portion for conveying the metal part out of the solvent bath. This is an efficient way for the metal part to be removed from the solvent bath.

[0070] Preferably, the conveyor belt conveys multiple electrodes. Electrodes preferably have a width of between about 3 cm and about 100 cm. Electrodes preferably have a length in the range of about 3 cm to about 25 m. In many cylindrical cells, a length of electrodes of several meters is wound into a coil. Such a wound electrode may be unwound prior to processing in a solvent. Electrodes preferably have a thickness in the range of about 50 pm to about 5 mm.

[0071] A conveyor belt allows multiple electrodes to be conveyed into the solvent bath. The processing of multiple electrodes in sequence can advantageously be performed in a continuous manner. The speed at which the conveyor belt is run can be selected such that each electrode has a suitable residence time in the solvent bath. The residence time may be selected in dependence on the solvent temperature, for example, for a solvent temperature between about 18°C to about 25°C, the residence time is preferably about 5 minutes to about 15 minutes.

[0072] The metal layer is preferably conveyed out of the solvent bath, preferably substantially none of the active material component is conveyed by the conveyor belt out of the solvent bath. When the conveyor belt is perforated, gridded or comprises multiple strands (such as an O- ring conveyor), the active material may preferably pass through gaps in the belt and sink to a base of the bath.

[0073] Preferably the metal layer is conveyed out of the bath as a metal foil, preferably a substantially intact metal foil. It is an advantage that the metal foil is substantially intact as it can then be easily collected, recycled and reused. It also helps with the separation of the active material from the metal layer that the metal layer is substantially intact and / or removable in the form of a foil as the metal does not contaminate the active material layer.

[0074] Preferably, the electrode is arranged on the conveyor belt such that the metal layer is above the active material. Such an arrangement is advantageous for permitting the metal layer to detach from the electrode and float to the surface of the solvent. Preferably, the active material layer is substantially intact when it is separated from the metal layer, this is for ease of removal, collection and recycling and / or reusing.

[0075] Preferably, the active material layer is removed from the metal layer in portions. It is advantageous that it is not necessary for the active material layer to be substantially intact as it can be further recycled in portions, preferably in particulate form.

[0076] The method preferably further comprises introducing the electrode into the solvent bath by lowering a perforated holder into the solvent. The electrode is preferably introduced into the solvent by automated means, for example a mechanical arm. Preferably the method further comprises treating the active material component with a solvent to remove impurities from the active material. Preferably the solvent is the same solvent as used for the treating the electrode. Preferably water is used to remove impurities. Preferably the active material component is treated for about 5 minutes to about 15 minutes.

[0077] The method preferably further comprises, prior to step (a), preparing the electrode for separation by removing the electrode from a cell. Removing the electrode from a cell preferably comprises cutting a battery casing. Removing the electrode from the cell is preferably an automated process, preferably by a robotic arm. Preferably the duration between the electrode being removed from the cell and the electrode being treated by a solvent is less than about 24 hours, preferably less than about 12 hours, preferably less than about 6 hours. An electrode removed from a cell may react in air such that delamination of the electrode layers is prevented.

[0078] In a further aspect, there is provided a method of separating an electrode for recycling, the electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the method comprising: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

[0079] The further aspect preferably incorporates any of the preferred features of the methods described herein. The further aspect preferably has analogous advantages to the aspect previously described. Further, it is an advantage that physical means are not required in the further aspect as the action of the solvent alone may cause the delamination of the electrode to form a metal component and an active material component. Optionally, physical means may be used in combination with the steps of the further aspect. In an example, abrasion of the active material layer may be used to delaminate the metal layer from the active material layer.

[0080] In a second aspect there is provided a method of producing an electrode for a cell, the method comprising: i) providing an active material component produced according to the first aspect; ii) mixing the active material component with a binder and solvent to form a slurry; iii) coating a metal layer with the slurry to form a coated metal; iv) drying the coated metal to form an electrode.

[0081] Disclosed herein is a method of producing an electrode for a cell, the method comprising: i) providing an active material produced according to the first aspect; ii) mixing the active material with a binder and solvent to form a slurry; iii) coating a metal layer with the slurry to form a coated metal; iv) drying the coated metal to form an electrode.

[0082] The method of separating provides collection of an active material component. This collected material can be used in the method of producing an electrode. The active material component produced according to the first aspect has the required electrochemical properties to be used directly to produce an electrode. For example, the chemical and physical properties of an active material component collected from a separated electrode and made into a slurry are comparable with a slurry prepared with new active materials.

[0083] Step (iv) preferably further comprises curing the binder. The curing of binder preferably comprises heating and / or applying pressure to the metal coated with slurry. Preferably the binder cures under ambient conditions so that no thermal or chemical processing is required.

[0084] Preferably, the active material comprises graphite, the binder comprises CMC and / or SBR and / or PAA, and the metal layer comprises copper, preferably wherein the binder comprises SBR / CMC. Such a combination is typical in commercial anodes.

[0085] In an alternative example, preferably the active material comprises lithium iron phosphate and the metal layer comprises aluminium, and the electrode formed is a cathode.

[0086] Disclosed herein is a method of producing an electrode for a cell, the method comprising: i) providing an active material component produced according to the first aspect; separating active material from the active material component by heat treatment or by treatment with a second solvent; ii) mixing the active material with a binder and solvent to form a slurry; iii) coating a metal layer with the slurry to form a coated metal; iv) drying the coated metal to form an electrode.

[0087] In a third aspect there is provided a method of producing a cell comprising assembling the electrode produced by the method of the second aspect into a cell. An anode and cathode may preferably be arranged on opposing sides of a separator and an electrolyte may be introduced.

[0088] In a fourth aspect there is provided a recycling process comprising a method of disassembling a cell as described in the second aspect to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the recycling process comprising: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

[0089] The recycling process according to the fourth aspect may further comprise a feature of the method according to the first aspect.

[0090] The recycling process according to the fourth aspect may further comprise a feature of the method according to the further aspect.

[0091] Preferably the recycling process is carried out using a solvent at a temperature below 20°C. This is advantageous as the boiling point of hydrogen fluoride (HF) is about 20°C. In an electrode comprising fluorine, or an electrode from a cell having an electrolyte comprising fluorine, HF may be produced when the electrode reacts with the solvent. HF is highly hazardous to human health and reacts with metal to form explosive hydrogen gas. It is desirable to minimise the formation of HF vapour in electrode recycling processes.

[0092] In a fifth aspect there is provided a process of recycling and reusing components of a cell comprising the method of disassembling a cell as described in previous aspects to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the process of recycling comprising: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; d) collecting the active material component; e) heating the active material component to form isolated active material; f) mixing the isolated active material, a second binder and a solvent to form a slurry; g) coating a metal film with the slurry to form a coated metal; and h) drying the coated metal to form a new electrode.

[0093] In an additional aspect there is provided a process of recycling and reusing components of a cell comprising the method of disassembling a cell as described in previous aspects to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the process of recycling comprising: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; d) collecting the active material component; e) treating the active material component with a second solvent to form isolated active material; f) mixing the isolated active material, a second binder and a solvent to form a slurry; g) coating a metal film with the slurry to form a coated metal; and h) drying the coated metal to form a new electrode.

[0094] The process of recycling and reusing components of a cell preferably further comprises processing the separated metal component into a recycled metal film and using the recycled metal film as the metal film in step (g). It is advantageous that the recycling process is closed loop (also known as circular), owning to the high yields and purity of the processed components.

[0095] The process of recycling and reusing components of a cell preferably further comprises a feature of any of the first to fourth aspects.

[0096] The process of recycling and reusing components of a cell preferably further comprises a step of assembling the new electrode into a cell.

[0097] In a sixth aspect there is provided an electrode obtainable by the method of the third aspect or obtainable by the process of the fifth aspect.

[0098] In a seventh aspect there is provided a cell obtainable by the process of the fifth aspect.

[0099] Figure 3 shows an example of a conveyor arrangement 300. The conveyor arrangement 300 may be used with a solvent bath, such as that shown in figure 1 , where the conveyor is positioned as conveyor 102. In the arrangement shown in figure 3, a plurality of conveyor belts 303 are disposed around rollers 302. The rollers may be referred to as pulleys. A tensioner pulley may be positioned to maintain tension in the conveyor belt 303. Each roller 302 is fixed by a fastener 301. Each roller 302 is rotatable about the respective fastener 301. An upper and lower conveyor belt arrangement is shown. The conveyor belt may be referred to as an O-ring. An electrode to be processed is input between the upper and lower conveyor belt arrangements. The electrode is conveyed between the rollers 302. A portion of the arrangement 304 is positioned in a solvent bath (not shown). The electrode at 304 is submerged in solvent. As the conveyor moves the electrode in the solvent, the metal layer and active material layer separate.

[0100] It is advantageous to process electrodes in such a reel-to-reel arrangement as there is a high throughput meaning that multiple electrodes can be processed in a short duration. The conveying of a separated metal component from the solvent permits simple collection of the metal for reuse.

[0101] Figure 4 shows a schematic section of the conveyor arrangement of figure 3. An electrode 200 comprising a metal layer 201 and active material layer 202 is shown passing between rollers. Conveyor belts 403 are conveyed by the rotation of rollers and in turn convey the electrode through sets of rollers. The rollers and belts may be arranged and tensioned such that pressure is applied to the electrode as it passes between rollers. The belt preferably comprises an elastomeric material and provides tension to the arrangement.

[0102] Advantageously, the conveyor may be arranged such that physical means, such as mechanical separation, for example abrasion, is not required to remove the metal layer from the electrode. Preferably the electrode is caused to delaminate by treatment in the solvent alone. Preferably abrasive brushes are not used.

[0103] Figure 5 shows a top-down schematic view of a multi-strand conveyor 500. Rollers 502 are disposed to convey an electrode 200 along a plurality of strands 503. An example of the roller arrangement viewed side-on is shown in figure 3. The strands may extend substantially parallel to a ground between rollers. The conveyor is arranged above a solvent bath 501. The rollers are arranged such that a pair of rollers are at least partially submerged in the solvent bath 501. The strands preferably slope from a higher roller to a roller in the solvent bath, as indicated by the dashed lines at 503a. allows solvent to be in contact with the bottom surface of the electrode. The strands 503 of the conveyor arrangement support the electrode 200 and convey the electrode into the solvent. Preferably the strands convey a separated metal component out of the solvent. The stands 503 are separated from each other to permit an active material component of the electrode to be in contact with the solvent and to pass through gaps between the strands.

[0104] Figure 6 shows an example of a conveyor arrangement in a solvent bath 606. Only part of the conveyor arrangement is shown, the electrode may be inserted or input (not shown) to the conveyor to be transported into a solvent. The surface of the solvent is indicated by dashed line 605. Preferably the conveyor is at least partly submerged in the solvent, preferably the conveyor is fully submerged in the solvent. A conveyor arrangement is shown having substantially parallel conveyors positioned such that an electrode passed between the upper and lower conveyor is in the solvent. First and second rollers 603, 604 are shown. The electrode delaminates in the solvent and is separated into a metal layer 601 and active material layer 602. The electrode is conveyed out from between the rollers 603, 604 and there is a high angle downward slope along which the separated active material layer is conveyed. The high angle may assist the separation of the layers. The separated components of the electrode may be conveyed out of the solvent by suitable means (not shown).

[0105] Figure 7 shows two scanning electron microscope (SEM) images of graphite as purchased and graphite separated from an electrode according to the method herein. Figure 7a shows ABP-200 graphite (purchased from NEI Corporation). Figure 7b shows graphite powder obtained by processing an electrode to delaminate the active material layer and separating the active material by treating with a solvent. The SEM imaging conditions for both figure 7a and 7b are 500x magnification, 20.0kV beam energy, and 10.0mm working distance. It can be seen from figure 7 that the graphite particle size is substantially the same after processing as in the virgin material. It can be seen that the particle morphology is substantially the same after processing as in the virgin material. Figure 7 demonstrates that material separated from an electrode by the method herein is of substantially the same high quality as unprocessed material suitable for use in making an electrode.

[0106] The aspects described herein address the problems with current processes used to recover electrode materials. The simplicity of the method of separating electrode components is particularly advantageous in producing high yield, high purity products, suitable for subsequent use without further refinement.

[0107] Within this specification, the term "about" means plus or minus 20%, more preferably plus or minus 10%, even more preferably plus or minus 5%, most preferably plus or minus 2%. Within this specification, the term "substantially" means a deviation of plus or minus 20%, more preferably plus or minus 10%, even more preferably plus or minus 5%, most preferably plus or minus 2%.

[0108] Within this specification, reference to “substantially” includes reference to “completely” and / or “exactly.” That is, where the word substantially is included, it will be appreciated that this also includes reference to the particular sentence without the word substantially.

[0109] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications are covered by the appended claims.

[0110] In this disclosure, when the subject of a phase is described as being "configured to" or “arranged to”, followed by a term defining a condition or function, this is used to indicate that the subject of the phrase is in a state in which it has that condition, or is able to perform that function, without the subject being modified or further configured.

[0111] Some implementations may be described using the expressions “one / an embodiment” or “one / an example,” along with their derivatives. These terms mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Moreover, unless otherwise noted the features described above are recognized to be usable together in any combination. Thus, any features discussed separately may be employed in combination with each other unless it is noted that the features are incompatible with each other.

[0112] The foregoing description of example embodiments has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims appended hereto. Future filed applications claiming priority to this application may claim the disclosed subject matter in a different manner and may generally include any set of one or more limitations as variously disclosed or otherwise demonstrated herein. Within this specification embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. For example, it will be appreciated that all preferred features described herein are applicable to all aspects of the invention described herein and vice versa.

[0113] CLAUSES

[0114] 1 . A method of separating an electrode for recycling, the electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the method comprising: a) treating the electrode with a solvent; b) removing the active material layer from the electrode by physical means to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

[0115] 2. The method of clause 1 , wherein the solvent comprises water and / or an organic solvent, preferably water.

[0116] 3. The method of clause 1 or clause 2, wherein the solvent comprises water, an alcohol, methyl ethyl ketone (MEK), N-Methyl-2-pyrrolidone (NMP), tetrahydrofuran (THF), chloroform, xylene, toluene, acetone, acetyl triethyl citrate (ATEC), butyrolactone (GBL), cyclohexanone, cyclopentanone, dibutyl phthalate, dibutyl sebacate, dibutyl carbonate, dibutyl phthalate, dihydrolevoglucosenone, dimethylacetamide, N,N-dimethylformamide, dimethylsulfoxide, 1 ,4-Dioxane, 3-Heptanone, hexamethyl phosphoramide, 3-Heptanone, methyl ethyl ketone, N-methyl-2-pyrrolidone, 3-octanone, 3-pentanone, propylene carbonate, tetra hydrofuran, tetramethylurea, triacetin, triethyl citrate, triethyl phosphate, trimethyl phosphate, N,N-tetrabutylsuccindiamide, alkali water, formamide, 1 ,4-Dioxane, 0.2 M aqueous hydrochloric acid (HCI), or a combination of two or more thereof, preferably water.

[0117] 4. The method of any of clauses 1 to 3, wherein the solvent is a polar solvent.

[0118] 5. The method of any preceding clause, wherein the binder comprises carboxymethyl cellulose (CMC), styrene-butadiene rubber (SBR), polyacrylic acid (PAA), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), or a combination of two or more thereof, preferably styrene-butadiene rubber / carboxymethyl cellulose (SBR / CMC), PVDF or a combination of two or more thereof.

[0119] 6. A method according to any preceding clause, wherein the binder comprises SBR / CMC and wherein the solvent comprises water, ethanol, acetone, MEK, or a combination of two or more thereof, preferably water.

[0120] 7. A method according to any preceding clause, wherein the binder comprises PAA and wherein the solvent comprises water.

[0121] 8. A method according to any preceding clause, wherein the binder comprises PVDF and wherein the solvent comprises N-Methyl-2-pyrrolidone (NMP), methyl ethyl ketone (MEK), N,N-dimethylformamide, dimethyl sulfoxide, propylene carbonate, tetrahydrofuran, or a combination of two or more thereof, preferably NMP or MEK, preferably NMP.

[0122] 9. A method according to any preceding clause, wherein the binder comprises PTFE, and wherein the solvent comprises N-Methyl-2-pyrrolidone (NMP), methyl ethyl ketone (MEK), N,N-dimethylformamide, dimethyl sulfoxide, propylene carbonate, tetrahydrofuran, or a combination of two or more thereof, preferably NMP or MEK, preferably NMP.

[0123] 10. The method of any preceding clause, wherein the metal layer comprises copper, iron, aluminium, magnesium, zinc, nickel, or a combination of two or more thereof, preferably copper or aluminium.

[0124] 11. The method of any preceding clause, wherein the active material layer comprises graphite, silicon, carbon black, sodium, lithium, iron, phosphorous, nickel, cobalt, manganese, niobium, or a combination of two or more thereof.

[0125] 12. The method of any preceding clause, wherein the electrode is an anode.

[0126] 13. The method of clause 12, wherein the metal layer comprises copper, the active material comprises graphite, the binder comprises SBR / CMC and the solvent comprises water.

[0127] 14. The method of any of clauses 1 to 11 , wherein the electrode is a cathode.

[0128] 15. The method of clause 14, wherein the metal layer comprises aluminium, the active material comprises nickel and the binder comprises polyvinylidene fluoride (PVDF) and / or polytetrafluoroethylene (PTFE), and wherein the solvent comprises N-Methyl-2-pyrrolidone (NMP).

[0129] 16. The method of clause 15, wherein the metal layer comprises aluminium and the active material comprises lithium iron phosphate or lithium manganese iron phosphate.

[0130] 17. The method of any preceding clause, wherein the step of removing the active material layer is performed by abrading the active material layer.

[0131] 18. The method of clause 17, wherein abrading the active material layer is performed by at least one of: a brush, preferably roller brushes, a scraper tool, a blade, a bar, a solvent jet, or an air jet.

[0132] 19. The method of clause 18, wherein the removal of the active material layer comprises passing the electrode through roller brushes disposed above and / or below the active material layer.

[0133] 20. The method of any preceding clause, wherein collecting the active material component comprises removing the active material component from the solvent, preferably by filtration, centrifugation, drying, or a combination of two or more thereof.

[0134] 21. The method according to clause 20, wherein the drying is performed between about 40°C to about 450°C, preferably about 100°C to about 300 °C, and / or wherein the drying is performed for about 30 minutes to about 8 hours, preferably about 1 hour to about 4 hours.

[0135] 22. The method according to clause 20, wherein the drying is performed at around room temperature to around 70°C under a pressure less than atmospheric pressure.

[0136] 23. The method of any preceding clause, wherein the method is performed in a solvent bath.

[0137] 24. The method of clause 23, wherein the solvent bath has a sloped base with a higher end and a lower end disposed at opposing sides of the sloped base.

[0138] 25. The method of clause 24, wherein the active material component is collected from a lowest portion of the sloped base. 26. The method of any preceding clause, wherein step (a) comprises immersing the electrode in a solvent, preferably wherein the solvent is provided in a solvent bath.

[0139] 27. The method of any preceding clause, wherein step (c) comprises removing the active material layer from the electrode in a solvent bath.

[0140] 28. The method of any preceding clause, wherein the proportion of surface area of the electrode that is exposed to the solvent is above about 50%, preferably above about 80%, more preferably above about 90%, more preferably above about 95%.

[0141] 29. The method as stated in any of clauses 23 to 28, wherein the electrode is conveyed into the solvent bath on a conveyor belt, preferably a perforated conveyor belt, a gridded conveyor belt or an O-ring conveyor.

[0142] 30. The method of clause 29, wherein the conveyor belt comprises an angled portion for conveying the electrode into the solvent bath, and / or wherein the conveyor belt comprises an angled portion for conveying the metal part out of the solvent bath.

[0143] 31. The method as stated in clause 29 or 30, wherein the metal component is conveyed by the conveyor belt out of the solvent bath.

[0144] 32. The method as stated in any of clauses 29 to 31 , wherein the electrode is arranged on the conveyor belt such that the metal layer is above the active material layer.

[0145] 33. The method of any of clauses 23 to 28, further comprising introducing the electrode into the solvent bath by lowering a perforated holder containing the electrode into the solvent bath.

[0146] 34. The method as stated in any preceding clause, further comprising, prior to step a), preparing the electrode for separation by removing the electrode from a cell.

[0147] 35. The method of clause 34, wherein removing the electrode from a cell comprises cutting a battery casing.

[0148] 36. The method as stated in clause 34 or 35, wherein removing the electrode from the cell is an automated process, preferably performed by a robotic arm. 37. A method of separating an electrode for recycling, the electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the method comprising: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

[0149] 38. The method of clause 37, wherein delaminating the active material layer comprises removing the active material layer from the electrode by physical means.

[0150] 39. The method according to any preceding clause, wherein the active material is removed or delaminated from the electrode in a single piece.

[0151] 40. The method according to clause 39, wherein the single piece is about at least 80 wt% of the active material layer, more preferably at least about 90 wt% of the active material layer, more preferably at least about 95 wt% of the active material layer.

[0152] 41 . The method according to clause 39 or 40, wherein the active material layer is not removed in small pieces, preferably a smallest piece of the active material removed from the electrode is greater than about 1 cm2, preferably greater than about 2 cm2.

[0153] 42. The method according to any preceding clause, wherein the pH of the solvent is greater than about 3, preferably greater than about 5, preferably greater than about 6, more preferably the solvent has a pH of about 7.

[0154] 43. The method according to any preceding clause, wherein the solvent does not comprise an acid.

[0155] 44. The method according to any preceding clause, wherein the binder is distributed substantially homogeneously throughout the active material layer.

[0156] 45. The method according to any preceding clause, wherein the electrode is treated with the solvent for a duration of about 3 minutes to about 2 hours, preferably for a duration of about 5 minutes to about 1 hour, preferably for a duration of about 5 minutes to about 15 minutes. 46. The method according to any preceding clause, further comprising purifying the active material component by treatment with a solvent.

[0157] 47. The method according to any preceding clause, wherein the solvent is at a temperature of about 10°C to about 60°C, preferably about 15°C to about 40°C, preferably about 18°C to about 25°C.

[0158] 48. The method according to any of clauses 37 to 47, further comprising the feature of any of clauses 1 to 36.

[0159] 49. A method of producing an electrode for a cell, the method comprising: i) providing an active material component produced according to any of clauses 1 to 48; ii) mixing the active material component with a binder and a solvent to form a slurry; iii) coating a metal layer with the slurry to form a coated metal; iv) drying the coated metal to form an electrode.

[0160] 50. The method of clause 49, wherein step (iv) comprises curing the binder.

[0161] 51 . The method of clause 49 or 50, wherein the active material component comprises graphite, wherein the binder comprises CMC and / or SBR and / or PAA, and wherein the metal layer comprises copper, preferably wherein the binder comprises SBR / CMC.

[0162] 52. A method of producing a cell comprising assembling the electrode produced by the method according to any of clauses 49 to 51 into a cell.

[0163] 53. A recycling process comprising a method of disassembling a cell to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the recycling process comprising preparing the electrode for separation by removing the electrode from a cell and: a) treating the electrode with a solvent; b) removing the active material layer from the electrode by physical means to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component. 54. A recycling process according to clause 53, further comprising a feature of any of clauses 1 to 48.

[0164] 55. A process of recycling and reusing components of a cell by disassembling a cell to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the recycling process comprising preparing the electrode for separation by removing the electrode from a cell and: a) treating the electrode with a solvent; b) removing the active material layer from the electrode by physical means to form a metal component and an active material component; c) collecting the metal component; d) collecting the active material component; e) heating the active material component to form isolated active material; f) mixing the isolated active material, a second binder and a solvent to form a slurry; g) coating a metal film with the slurry to form a coated metal; and h) drying the coated metal to form a new electrode.

[0165] 56. The process of recycling and reusing components of a cell according to clause 55, further comprising processing the separated metal component into a recycled metal film and using the recycled metal film as the metal film in step (g).

[0166] 57. The process of recycling and reusing components of a cell according to clause 55 or clause 56, further comprising a feature of any of clauses 1 to 48.

[0167] 58. The process of recycling and reusing components of a cell according to any of clauses 55 to 57, further comprising the step of assembling the new electrode into a cell.

[0168] 59. An electrode obtainable by the method of any of clauses 49 to 51 or obtainable by the process of any of clauses 53 to 58.

[0169] 60. A cell obtainable by the process of clause 58.

[0170] 61. The method of clause 37, further comprising treating the active material component with a second solvent to separate the active material from the binder.

Claims

CLAIMS1 . A method of separating an electrode for recycling, the electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the method comprising: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

2. The method of claim 1 , wherein the solvent comprises water, methyl ethyl ketone (MEK), N-Methyl-2-pyrrolidone (NMP), tetrahydrofuran (THF), chloroform, xylene, toluene, acetone, or a combination of two or more thereof, preferably water.

3. The method of any of claim 1 or 2, wherein the solvent is a polar solvent.

4. The method of any preceding claim, wherein the binder comprises carboxymethyl cellulose (CMC), styrene-butadiene rubber (SBR), polyacrylic acid (PAA), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), or a combination of two or more thereof, preferably styrene-butadiene rubber / carboxymethyl cellulose (SBR / CMC), PVDF or a combination of two or more thereof.

5. The method of any preceding claim, wherein the metal layer comprises copper, iron, aluminium, magnesium, zinc, nickel, or a combination of two or more thereof, preferably copper or aluminium.

6. The method of any preceding claim, wherein the active material layer comprises graphite, silicon, carbon black, sodium, lithium, iron, phosphorous, nickel, cobalt, manganese, niobium, or a combination of two or more thereof.

7. The method of any preceding claim, wherein the electrode is an anode.

8. The method of claim 7, wherein the metal layer comprises copper, the active material comprises graphite, the binder comprises SBR / CMC and the solvent comprises water.

9. The method of any of claims 1 to 6, wherein the electrode is a cathode.

10. The method of claim 9, wherein the metal layer comprises aluminium, the active material comprises nickel and the binder comprises polyvinylidene fluoride (PVDF) and / or polytetrafluoroethylene (PTFE), and wherein the solvent comprises N-Methyl-2-pyrrolidone (NMP).

11. The method of any preceding claim, wherein delaminating the active material layer comprises removing the active material layer from the electrode by physical means.

12. The method of claim 11 , wherein removing the active material layer is performed by abrading the active material layer.

13. The method of any preceding claim, wherein collecting the active material component comprises removing the active material component from the solvent, preferably by filtration, centrifugation, drying, or a combination of two or more thereof.

14. The method according to claim 13, wherein the drying is performed between about 40°C to about 450°C, preferably about 100°C to about 300 °C, and / or wherein the drying is performed for about 30 minutes to about 8 hours, preferably about 1 hour to about 4 hours.

15. The method according to claim 13, wherein the drying is performed at around room temperature to around 70°C under a pressure less than atmospheric pressure.

16. The method of any preceding claim, wherein the method is performed in a solvent bath, wherein the solvent bath has a sloped base with a higher end and a lower end disposed at opposing sides of the sloped base, and wherein the active material component is collected from a lowest portion of the sloped base.

17. The method of any preceding claim, wherein step (a) comprises immersing the electrode in a solvent, preferably wherein the solvent is provided in a solvent bath.

18. The method of any preceding claim, wherein the proportion of surface area of the electrode that is exposed to the solvent is above about 50%, preferably above about 80%, more preferably above about 90%, more preferably above about 95%.

19. The method as claimed in any of claims 15 to 18, wherein the electrode is conveyed into the solvent bath on a conveyor belt, preferably a perforated conveyor belt, a gridded conveyor belt or an O-ring conveyor.

20. The method as claimed in any preceding claim, further comprising, prior to step a), preparing the electrode for separation by removing the electrode from a cell.

21. The method as claimed in any preceding claim, further comprising treating the active material component with a second solvent to separate the active material from the binder.

22. A method of producing an electrode for a cell, the method comprising: i) providing an active material component produced according to any of claims 1 to 21 ; ii) mixing the active material component with a binder and a solvent to form a slurry; iii) coating a metal layer with the slurry to form a coated metal; iv) drying the coated metal to form an electrode.

23. A recycling process comprising a method of disassembling a cell to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the recycling process comprising preparing the electrode for separation by removing the electrode from a cell and: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; and d) collecting the active material component.

24. A process of recycling and reusing components of a cell by disassembling a cell to obtain an electrode comprising a metal layer and an active material layer, wherein the active material layer comprises an active material and a binder, the recycling process comprising preparing the electrode for separation by removing the electrode from a cell and: a) treating the electrode with a solvent; b) delaminating the active material layer from the electrode to form a metal component and an active material component; c) collecting the metal component; d) collecting the active material component;e) heating the active material component to form isolated active material, or treating the active material component with a second solvent to form isolated active material; f) mixing the isolated active material, a second binder and a solvent to form a slurry; g) coating a metal film with the slurry to form a coated metal; and h) drying the coated metal to form a new electrode.

25. An electrode obtainable by the method of claim 22 or 24.

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