Applied Materials, Inc.

Joseph G Gordon

Subramanya P Herle

Fei C Wang

Robert Z Bachrach

Connie P Wang

Michael C Kutney

Siqing Lu

Hooman Bolandi

Victor Pebenito

GirishKumar Gopalakrishnan Nair

The present invention relates generally to electrochemical energy storage devices such as Li-ion batteries, and more particularly to a method of providing uniform ceramic coatings with controlled thicknesses for separators in such storage devices. Some embodiments of the invention utilize a layer by layer coating of nano/micro-sized particles dispersed in a solvent, which can be aqueous or non-aqueous. Other embodiments of the invention utilize a dry process such as PVD for depositing a ceramic film on a porous polyolefin separator. According to certain aspects of the invention, advantages of this approach include the ability to achieve a denser more uniform film with better controlled thickness with less waste and higher yield than current ceramic coating technology. An advantage of a ceramic coated separator is increased safety of cells.

Ceramic coating on battery separators

A method and apparatus for forming battery active material on a substrate are disclosed. In one embodiment, an apparatus for depositing a battery active material on a surface of a substrate includes a substrate conveyor system for transporting the substrate within the apparatus, a material spray assembly disposed above the substrate conveyor system, and a first heating element disposed adjacent to the material spray assembly above the substrate conveyor system configured to heat the substrate. The material spray assembly has a 2-D array of nozzles configured to electrospray an electrode forming solution on the surface of the substrate.

Complex showerhead coating apparatus with electrospray for lithium ion battery

The present invention generally relates to using water-based binders for high voltage cathode materials, such as LMNO (spinel LiNiMnO), in Li-ion batteries. An example of a water compatible polymer binder according to some embodiments of the present invention is a combination of CMC (carboxymethylcellulose) and a second water compatible polymer that produce coatings of adequate thickness and loading (mAh/cm). A method of forming a cathode for a Li-ion battery may include: preparing an aqueous solution of CMC; mixing together LMNO and carbon black; combining the LMNO and carbon black mixture with the CMC solution, an aqueous polyacrylic solution and distilled water, and mixing to form a slurry; coating a conductive substrate with the slurry; and drying the coated substrate, forming a cathode layer on the substrate. Furthermore, this invention describes a cathode for Li-ion batteries and tools for carrying out the above method.

Water-based binder for high voltage cathode material for Li-ion battery

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San Jose, CA, United States of America

Joseph G Gordon