WO2022104213A1

WO2022104213A1 - Covalently bonded coatings for foils used as current collectors in energy storage devices

Info

Publication number: WO2022104213A1
Application number: PCT/US2021/059390
Authority: WO
Inventors: Martti Kaempgen
Original assignee: Novelis Inc.
Priority date: 2020-11-16
Filing date: 2021-11-15
Publication date: 2022-05-19

Abstract

Described are treated metal products and battery components and methods for making metal treated metal products and energy storage device components. The treated metal products may be used in battery components, such as current collectors in lithium ion batteries, supercapacitors, or hybrid capacitors, for example. Optionally, the current collectors may be coated with an electrode active material to generate an electrode. The treatments applied to the metal product may form a covalently bonded layer over a surface of the metal product and allow the metal product to exhibit advantageous characteristics, such as good corrosion resistance, high conductivity, and good adhesion of electrode active material layers, for example, when used as or in an energy storage component (e.g., a current collector or a battery electrode).

Description

COVALENTLY BONDED COATINGS FOR FOILS USED AS CURRENT

COLLECTORS IN ENERGY STORAGE DEVICES

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63/198,825, filed on November 16, 2020, which is hereby incorporated by reference in its entirety.

FIELD

[0002] The present disclosure relates to metallurgy generally and more specifically to treated metal substrates for use as current collectors in energy storage devices, such as battery systems, double layer capacitors, and hybrid capacitors.

BACKGROUND

[0003] Many batteries employ metallic current collectors for delivering charge to or from battery electrode active materials. Lithium ion batteries, for example, may employ copper and aluminum current collectors. These metal current collectors may be subject to corrosion during normal battery operation and, thus, improved current collectors are needed.

SUMMARY

[0004] The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings and each claim.

[0005] In an aspect, energy storage devices and energy storage device components are described herein. Example energy storage devices include batteries, double layer capacitors, also referred to herein as supercapacitors, and hybrid capacitors, also referred to herein as asymmetric capacitors. The energy storage devices may employ a metal foil, for example, used as a current collector and various other components. In one example, an energy storage device component comprises a current collector, and a coating layer disposed over a surface of the current collector. Advantageously, the coating layer may include molecules that are covalently bonded to the surface of the current collector, which may provide enhancements in resisting corrosion, conductivity, and adhesion of other materials to the current collector. [0006] In embodiments, the current collector comprises a metal foil. For example, the current collector may comprise an aluminum alloy or a copper alloy. Example current collectors include those having thickness of from 0.005 mm to 0.05 mm, such as from 0.005 mm to 0.01 mm, from 0.005 mm to 0.015 mm, from 0.005 mm to 0.02 mm, from 0.005 mm to 0.025 mm, from 0.005 mm to 0.03 mm, from 0.005 mm to 0.035 mm, from 0.005 mm to 0.04 mm, from 0.005 mm to 0.045 mm, from 0.01 mm to 0.015 mm, from 0.01 mm to 0.02 mm, from 0.01 mm to 0.025 mm, from 0.01 mm to 0.03 mm, from 0.01 mm to 0.035 mm, from 0.01 mm to 0.04 mm, from 0.01 mm to 0.045 mm, from 0.01 mm to 0.05 mm, from 0.015 mm to 0.02 mm, from 0.015 mm to 0.025 mm, from 0.015 mm to 0.03 mm, from 0.015 mm to 0.035 mm, from 0.015 mm to 0.04 mm, from 0.015 mm to 0.045 mm, from 0.015 mm to 0.05 mm, from 0.02 mm to 0.025 mm, from 0.02 mm to 0.03 mm, from 0.02 mm to 0.035 mm, from 0.02 mm to 0.04 mm, from 0.02 mm to 0.045 mm, from 0.02 mm to 0.05 mm, from 0.025 mm to 0.03 mm, from 0.025 mm to 0.035 mm, from 0.025 mm to 0.04 mm, from 0.025 mm to 0.045 mm, from 0.025 mm to 0.05 mm, from 0.03 mm to 0.035 mm, from 0.03 mm to 0.04 mm, from 0.03 mm to 0.045 mm, from 0.03 mm to 0.05 mm, from 0.035 mm to 0.04 mm, from 0.035 mm to 0.045 mm, from 0.035 mm to 0.05 mm, from 0.04 mm to 0.045 mm, from 0.04 mm to 0.05 mm, or from 0.045 mm to 0.05 mm.

[0007] Advantageously, the coating layer may comprise molecules having different moieties that function for different purposes, such as for adhering to the surface of the current collector, for resisting corrosion, for improving adhesion of an overlayer, or the like. For example, the coating layer may comprise multifunctional molecules including a first functional group for covalently bonding to the current collector and a second functional group. Optionally, the first functional group comprises a hydroxyl substituted silicon, a hydroxyl substituted phosphorous, a hydrogen substituted silicon, or a hydrogen substituted phosphorous. Useful second functional group includes those comprising an adhesion promoter group, a corrosion inhibitor group, or a conductivity promoter group. Optionally, the second functional group comprises a hydrophobic group or a nonpolar group. Example second functional groups may comprise one or more R groups, such as an R group that is or comprises a substituted or un substituted, saturated or unsaturated aliphatic group or a substituted or unsubstituted aromatic group. Optionally, R is a polymeric group, a polymeric precursor group, an inorganic acidic group, an inorganic basic group, an inorganic neutral group, or an ion coordination group. Example multifunctional molecules include, but are not limited to, those comprising a substituted silane, a substituted silanol, a substituted phosphate or phosphate ester, a substituted phosphonate, or a phosphoric acid.

[0008] The coating layer may have any suitable configuration. The coating layer may completely or partially coat one or more surface of the current collector, for example, Optionally, the coating layer comprises a monolayer. Optionally, the coating layer comprises a bilayer. Optionally, the coating layer comprises a thin film. The coating layer may, for example, have a thickness of from 1 nm to 1 pm, such as from 1 nm to 5 nm, from 1 nm to 10 nm, from 1 nm to 50 nm, from 1 nm to 100 nm, from 1 nm to 100 nm, from 1 nm to 500 nm, from 5 nm to 10 nm, from 5 nm to 50 nm, from 5 nm to 100 nm, from 5 nm to 500 nm, from 5 nm to 1 pm, from 10 nm to 50 nm, from 10 nm to 100 nm, from 10 nm to 500 nm, from 10 nm to 1 pm, from 50 nm to 100 nm, from 50 nm to 500 nm, from 50 nm to 1 pm, from 100 nm to 500 nm, from 100 nm to 1 pm, or from 500 nm to 1 pm. Thicknesses greater than 1 pm may also be used (e.g. up to 5 pm, up to 10 pm, up to 50 pm or up to 100 pm).

[0009] Additional materials may optionally be placed over the coating layer. For example, in some embodiments, an energy storage device or device component may comprise an electrode active material layer disposed over the coating layer. Example electrode active material layers may comprise one or more of an electrode active material, a conductive additive, or a binder. Example electrode active material layers may have any suitable thickness. Optionally, electrode active material layers for some embodiments may have a thickness of from 1 pm to 50 mm. For example, a thickness for an electrode active material layer may be from 1 pm to 5 pm, from 1 pm to 10 pm, from 1 pm to 50 pm, from 1 pm to 100 pm, from 1 pm to 500 pm, from 1 pm to 1 mm, from 1 pm to 5 mm, from 1 pm to 10 mm, from 5 pm to 10 pm, from 5 pm to 50 pm, from 5 pm to 100 pm, from 5 pm to 500 pm, from 5 pm to 1 mm, from 5 pm to 5 mm, from 5 pm to 10 mm, from 5 pm to 50 mm, from 10 pm to 50 pm, from 10 pm to 100 pm, from 10 pm to 500 pm, from 10 pm to 1 mm, from 10 pm to 5 mm, from 10 pm to 10 mm, from 10 pm to 50 mm, from 50 pm to 100 pm, from 50 pm to 500 pm, from 50 pm to 1 mm, from 50 pm to 5 mm, from 50 pm to 10 mm, from 50 pm to 50 mm, from 100 pm to 500 pm, from 100 pm to 1 mm, from 100 pm to 10 mm, from 100 pm to 50 mm, from 500 pm to 1 mm, from 500 pm to 5 mm, from 500 pm to 10 mm, from 500 pm to 50 mm, from 1 mm to 5 mm, from 1 mm to 10 mm, from 1 mm to 50 mm, from 5 mm to 10 mm, from 5 mm to 50 mm, or from 10 mm to 50 mm.

[0010] Optionally, a conductive layer may be positioned between the coating layer and the electrode active material layer, such as a conductive layer that comprises one or more of a carbonaceous material or a binder. Example conductive layers may have any suitable thickness, including from 10 nm to 2 mm, such as from 10 nm to 50 nm, from 10 nm to 100 nm, from 10 nm to 500 nm, from 10 nm to 1 pm, from 10 nm to 5 pm, from 10 nm to 10 pm, from 10 nm to 50 pm, from 10 nm to 100 pm, from 10 nm to 500 pm, from 10 nm to 1 mm, from 50 nm to 100 nm, from 50 nm to 500 nm, from 50 nm to 1 pm, from 50 nm to 5 pm, from 50 nm to 10 pm, from 50 nm to 50 pm, from 50 nm to 100 pm, from 50 nm to 500 pm, from 50 nm to 1 mm, from 50 nm to 2 mm, from 100 nm to 500 nm, from 100 nm to 1 pm, from 100 nm to 5 pm, from 100 nm to 10 pm, from 100 nm to 50 pm, from 100 nm to 100 pm, from 100 nm to 500 pm, from 100 nm to 1 mm, from 100 nm to 2 mm, from 500 nm to 1 pm, from 500 nm to 5 pm, from 500 nm to 10 pm, from 500 nm to 50 pm, from 500 nm to 100 pm, from 500 nm to 500 pm, from 500 nm to 1 mm, from 500 nm to 2 mm, from 1 pm to 5 pm, from 1 pm to 10 pm, from 1 pm to 50 pm, from 1 pm to 100 pm, from 1 pm to 500 pm, from 1 pm to 1 mm, from 1 pm to 2 mm, from 5 pm to 10 pm, from 5 pm to 50 pm, from 5 pm to 100 pm, from 5 pm to 500 pm, from 5 pm to 1 mm, from 5 pm to 2 mm, from 10 pm to 50 pm, from 10 pm to 100 pm, from 10 pm to 500 pm, from 10 pm to 1 mm, from 10 pm to 2 mm, from 50 pm to 100 pm, from 50 pm to 500 pm, from 50 pm to 1 mm, from 50 pm to 2 mm, from 100 pm to 500 pm, from 100 pm to 1 mm, from 100 pm to 2 mm, from 500 pm to 1 mm, from 500 pm to 2 mm, or from 1 mm to 2 mm. Example carbonaceous materials include graphite, carbon black, graphene, carbon nanotubes, carbon nanohorns, nanowires, fullerenes, and mixtures thereof.

[0011] Optionally, energy storage devices or device components may include additional materials, layers, or structures, such as additional electrode active layers, an electrolyte, and a separator. In one embodiment, the energy storage device or device component comprises a battery including a second electrode active layer and an electrolyte, with the electrolyte and the separator positioned between the first electrode active layer and the second electrode active layer.

[0012] In another aspect, methods are also described herein, such as methods of making energy storage devices and energy storage device components. In one embodiment, a method of this aspect comprises providing a current collector and subjecting a surface of the current collector to a reactive coating process to generate a coating layer over the surface of the current collector, wherein molecules of the coating layer are covalently bonded to the surface of the current collector during the reactive coating process. Optionally, a method of this aspect may comprise or further comprise subjecting the current collector and the coating layer to a coating process to form an electrode active material layer over the coating layer. Optionally, a method of this aspect may comprise or further comprise subjecting the current collector and the coating layer to a coating process to form a conductive layer over the coating layer, wherein the conductive layer comprises one or more of a carbonaceous material or a binder. Optionally, a method of this aspect may comprise or further comprise subjecting the current collector, the coating layer, and the conductive layer to another coating process to form an electrode active material layer over the conductive layer. Any suitable coating process may be used to form various layers according to the methods described herein. For example, one or more coating processes may comprise an immersion coating processes, a roll-to-roll coating processes, a spray coating processes, or a vacuum deposition processes. Optionally, a product of the methods of this aspect may be any of the energy storage devices or energy storage device components described herein.

[0013] Other objects and advantages will be apparent from the following detailed description of non-limiting examples.

BRIEF DESCRIPTION OF THE FIGURES

[0014] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0015] FIG. 1 provides a schematic illustration of an example battery cell

[0016] FIG. 2 provides a schematic overview of an immersion coating process for making a battery component.

[0017] FIG. 3 provides a schematic overview of an exemplary process for making an example battery component

[0018] FIG. 4 provides a schematic overview of a roll-coating process for making a battery component.

[0019] FIG. 5 provides a schematic illustration of another example battery cell.

DETAILED DESCRIPTION

[0020] Described herein are treated metal products and energy storage device components and methods for making metal treated metal products and energy storage device components, such as battery components, double layer capacitor (i.e., supercapacitor) components, and hybrid or asymmetric capacitor components. The treated metal products may be used in energy storage devices, such as current collectors in lithium ion batteries, supercapacitors, or hybrid capacitors, for example. Optionally, the current collectors may be coated with a battery electrode active material to generate a battery electrode. Similarly, the current collectors may be coated with a capacitor active material to generate a supercapacitor or hybrid capacitor electrode. The treatments applied to the metal product may form a covalently bonded layer over a surface of the metal product and allow the metal product to exhibit advantageous characteristics, such as improved corrosion resistance, improved conductivity, and improved adhesion of electrode active material layers, for example, when used as or in an energy storage device component (e.g., a current collector, a battery electrode, a supercapacitor or hybrid capacitor electrode).

[0021] The metal product may correspond to a metal sheet or foil, such as used as a current collector in a battery in some examples. The current collector may be used to provide charge to or receive charge from an electrode active material deposited or coated over the current collector. FIG. 1 provides a schematic overview of an example battery cell 100. Battery cell 100 includes first current collector 105, first active material layer 110, separator 115, electrolyte 120, second active material layer 125, and second current collector 130.

[0022] In embodiments, first active material layer 110 may comprise a cathode of battery cell 100 and second active material layer 125 may comprise an anode of battery cell 100. Example materials for first active material layer 110 in a lithium ion battery system may include, but are not limited to, LiCoCh. First current collector 105 may, for example, comprise aluminum or an aluminum alloy. Example materials for second active material layer 125 may include, but are not limited to, carbon or graphite. Optionally, first active material layer 110 and/or second active material layer 125 may further include conductive additives or binders. Second current collector 130 may, for example, comprise copper or a copper alloy. Separator 115 may, for example, comprise a non-electrically-conductive porous material, such as a porous polymeric material (e.g., a porous polypropylene or polyethylene membrane), glass fibers, ceramic materials, or the like. Electrolyte 120 may comprise a lithium salt dissolved in an organic solvent, such as LiPFe in ethylene carbonate or propylene carbonate. Identification of these materials as example components of battery cell 100 is not intended to be limiting, and other known active material layer components, separator materials, and electrolyte components may be used in battery cell 100. [0023] Battery cell 100 is illustrated with first active material layer 110 directly deposited onto first current collector 105 and with second active material layer 125 directly deposited onto second current collector 130. In some embodiments, such a configuration may result in corrosion of the first current collector 105 and/or second current collector 130. For example, during operation and/or storage of the battery cell, the working potential difference between the first active material layer 110 and the second active material layer 125 may be large, such as up to around 4 volts; similarly, charging voltages used for charging rechargeable battery cells may be as high as around 4.2 volts. At these potentials, degradation of the electrolyte may occur, resulting in formation of corrosive components. Additionally, during operation and/or storage of the battery cell, heat may be generated within the cell or provided from outside of the cell. If the electrolyte temperature is elevated too much, thermal decomposition of the electrolyte may occur, resulting in formation of corrosive components. Further, hydrolysis of components of the electrolyte may occur, such as by water entering into battery cell 100 through leaks or damage in the casing or container of battery cell 100 or by water being present or introduced during the manufacturing process, also forming corrosive components. Example corrosive components may include, for example hydrogen fluoride (HF), which may attack and degrade the current collector. Although FIG. 1 illustrates a battery cell, similar issues may exist with other energy storage devices, such as supercapacitors and hybrid capacitors.

[0024] The present invention overcomes these disadvantages by employing a protective treatment layer covalently bonded to the metal current collector and between the metal current collector and the active material layer. Covalent bonding between molecules of the treatment layer and the current collector may provide for a strongly adhered treatment layer that is extremely thin (e.g., about a monolayer) and that has limited susceptibility to being removed during processing and subsequent coating of the current collector. In addition to improving corrosion resistance, the protective treatment layer may also provide for improved adhesion between the active material layer and the current collector. Further, by improving adhesion, certain components of the active material layer, such as conductive additives or binders, may be reduced, providing for improved concentration of the active material in the active material layer, improved conductivity, and improved energy storage device capacity.

Definitions and Descriptions:

[0025] As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0026] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “7xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0027] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0028] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0029] As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0030] As used herein, a foil generally refers to a metal product having a thickness less than about 0.2 mm. For example, a foil may have a thickness of less than about 0.2 mm, less than about 0.15 mm, less than about 0.10 mm, less than about 0.05 mm, less than about 0.04 mm, less than about 0.03 mm, less than about 0.02 mm, or less than about 0.01 mm (e.g., about 0.006 mm).

[0031] As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method. [0032] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C. As used herein, the meaning of “ambient conditions” can include temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere in between. For example, barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.

[0033] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Unless stated otherwise, the expression “up to” when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt.%).

[0034] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise. Methods of Producing Metal Products

[0035] Metal substrates can be cast using any suitable casting method known to those of ordinary skill in the art. As a few non-limiting examples, the casting process can include a Direct Chill (DC) casting process or a Continuous Casting (CC) process. The continuous casting system can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls or blocks), a casting cavity between the pair of moving opposed casting surfaces, and a molten metal injector. The molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity.

[0036] A cast metal product can be processed by any means known to those of ordinary skill in the art. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment, and optional pre-aging and annealing steps. [0037] The cast metal products described herein can also be used to make products in the form of metal sheets, plates, or other suitable products. For example, a cast metal product may be subjected to one or more hot rolling or cold rolling processes to generate a rolled metal product.

Treating and Coating Methods

[0038] Metal products may be subjected to one or more treatment processes and/or one or more coating processes to form a battery component. In some examples, methods of treating and/or coating metal products, including aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel, among others, and the resultant treated metals and/or coated metal products, are described herein. In some examples, the metal products used in the methods and battery components described herein include aluminum alloys, for example, Ixxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys. In some examples, the metal products used in the methods and battery components include nonferrous materials, including aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, or any other suitable metal, or combination of metals. Monolithic as well as non-monolithic, such as roll-bonded materials, cladded alloys, clad layers, composite materials, such as but not limited to carbon fiber-containing materials, or various other materials are also useful with the methods and battery components described herein. In some examples, aluminum alloys containing iron are useful with the methods and battery components described herein.

[0039] By way of non-limiting example, exemplary Ixxx alloys for use in the methods and battery components described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

[0040] Non-limiting exemplary 2xxx series alloys for use in the methods and battery components described herein can include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

[0041] Non-limiting exemplary 3xxx series alloys for use in the methods and battery components described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.

[0042] Non-limiting exemplary 4xxx series alloys for use in the methods and battery components described herein can include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0043] Non-limiting exemplary 5xxx series alloys for use in the methods and battery components described herein can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

[0044] Non-limiting exemplary 6xxx series alloys for use in the methods and battery components described herein can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0045] Non-limiting exemplary 7xxx series alloys for use in the methods and battery components described herein can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0046] Non-limiting exemplary 8xxx series alloys for use in the methods and battery components described herein can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

[0047] In some examples, the metal products used in the methods and battery components may include those comprising recycled materials. For example, in some cases, recycled aluminum alloys, such as from used beverage can (UBC) scrap is used in preparing the metal products used in the methods and battery components described herein. In some cases, the metal product may include at least 50% of a recycled aluminum, such as equal to or greater than 60%, equal to or greater than 70%, equal to or greater than 80%, or equal to or greater than 90%. The recycled aluminum can comprise UBC scrap containing a mixture of recycled metal from can ends and can bodies. UBC scrap, for example, generally contains a mixture of metal from various alloys, such as metal from can bodies (e.g., 3104, 3004, or other 3xxx aluminum alloy) and can ends (e.g., 5182 or other 5xxx aluminum alloy). Other recycled scrap includes other mixtures of alloys. Recycled scrap can contain other impurities and alloying elements, which end up in the metal product when the recycled scrap is melted and processed into a metal product.

[0048] Optionally, the recycled scrap can be modified with one or more additional elements to prepare the metal product. In some examples, it can be desirable to add further magnesium (Mg) and/or other alloying elements to the recycled scrap, which can result in a recycled content alloy with improved castability or improved metallurgical properties of the end metal product. For example, added Mg can increase the formability and strength of the metal product.

[0049] Optionally, the recycled scrap can be modified with one or more additional elements to prepare the recycled content alloys. In some examples, it can be desirable to add further magnesium (Mg) and/or other alloying elements to the recycled scrap. In the case of adding Mg to a recycled content alloy, this may improve castability and/or improve metallurgical properties of the end metal product as compared to the recycled scrap without added Mg. In some examples, added Mg can increase the formability and strength of the metal product. In some examples, Mg can be added to the recycled scrap to achieve, in a recycled content alloy, a percentage of Mg of from about 0.50% to about 7.0% based on the total weight of the alloy (e.g., from about 1.5% to about 6.0%, from about 2.0% to about 5.0%, from about 2.5% to about 4.5%, or from about 3.0% to about 4.0%).

[0050] In some examples, the alloys described herein include Mg in an amount of from about 0.50% to about 7.0% (e.g., from about 1.0% to about 5.0%, from about 1.4% to about 3.0%, from about 1.5% to about 2.6%, or from about 1.6% to about 2.5%) based on the total weight of the alloy. For example, the alloy can include 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%,

0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%,

0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%,

0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%,

1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%,

2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%,

4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, 5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%,

5.7%, 5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9%, or 7.0%

Mg. All are expressed in wt.%.

[0051] In some examples, the alloys described herein include Cu in an amount of from about 0.01% to about 1.0% (e.g., from about 0.05% to about 1.0%, from about 0.1% to about 0.9%, from about 0.2 to about 0.8%, from about 0.15% to about 0.40%, or from about 0.20% to about 0.35%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%,

0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%,

0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 033%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%,

0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%,

0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%,

0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%,

0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%,

0.97%, 0.98%, 0.99%, or 1.0% Cu. All are expressed in wt.%.

[0052] In some examples, the alloys described herein include iron (Fe) in an amount of from about 0.15% to about 0.8% (e.g., from about 0.25% to about 0.7% or from about 0.3% to about 0.6%) based on the total weight of the alloy. For example, the alloy can include 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 033%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%,

0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%,

0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%,

0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80% Fe. All are expressed in wt.%.

[0053] In some examples, the alloys described herein include manganese (Mn) in an amount of from about 0.01% to about 1.2% (e.g., from about 0.05% to about 1.0%, from about 0.1% to about 0.9%, or from about 0.2% to about 0.7%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%,

0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%,

0.31%, 0.32%, 033%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%,

0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%,

0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%,

0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%,

0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.0%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, or 1.20% Mn. All are expressed in wt.%.

[0054] In some examples, the alloys described herein include Si in an amount up to about 1.5 wt.% (e.g., from about 0.01% to about 1.50%, from about 0.20% to about 1.0%, or from about 0.3% to about 0.9%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%,

0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%,

0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 033%, 0.34%, 0.35%,

0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%,

0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%,

0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%,

0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%,

0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%,

0.96%, 0.97%, 0.98%, 0.99%, 1.0%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%,

1.08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%,

1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, 1.30%, 1.31%,

1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.40%, 1.41%, 1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%, or 1.50% Si. In some cases, Si is not present in the alloy (i.e., 0%). All are expressed in wt.%.

[0055] In some examples, the alloys described herein include titanium (Ti) in an amount up to about 0.2% (e.g., from about 0.01% to about 0.15% or from about 0.02% to about 0.1%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, or 0.20% Ti. In some cases, Ti is not present in the alloy (i.e., 0%). All are expressed in wt.%.

[0056] In some examples, the alloys described herein include zinc (Zn) in an amount of from about 0% to about 6.0% (e.g., from about 0.01% to about 5.0% or from about 0.02% to about 3.0%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%,

0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%,

0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%,

0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%,

0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%,

0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%,

0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%,

0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%,

0.98%, 0.99%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%,

3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%,

5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, or 6.0% Zn. In some cases,

Zn is not present in the alloy (i.e., 0%). All are expressed in wt.%.

[0057] In some examples, the alloys described herein include chromium (Cr) in an amount up to about 0.30% (e.g., from about 0.01% to about 0.25% or from about 0.02% to about 0.1%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, or 0.30% Cr. In some cases, Cr is not present in the alloy (i.e., 0%). All are expressed in wt.%.

[0058] In some examples, the alloys described herein include zirconium (Zr) in an amount of from about 0% to about 0.15% (e.g., from about 0.01% to about 0.1% or from about 0.02% to about 0.05%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%,

0.11%, 0.12%, 0.13%, 0.14%, or 0.15% Zr. In some cases, Zr is not present in the alloy (i.e., 0%). All are expressed in wt.%.

[0059] Optionally, the alloy compositions described herein can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below, or 0.01% or below for each impurity. These impurities may include, but are not limited to, Sn, Ga, Ca, Bi, Na, Pb, Li, W, Mo, Ni, V or combinations thereof. Accordingly, Sn, Ga, Ca, Bi, Na, Pb, Li, W, Mo, Ni, or V may be present in alloys in amounts of 0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below or 0.01% or below. In some cases, the sum of all impurities does not exceed 0.15% (e.g., 0.10%). All expressed in wt.%. The remaining percentage of the alloy beyond any specified elements and impurities may be aluminum.

[0060] In some examples, suitable alloys for use in the metal products containing recycled content can be a Ixxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, an 8xxx series aluminum alloy, or any combination thereof. The Ixxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, or 8xxx series aluminum alloy can be modified to include amounts of Mg, Cu, Fe, Mn, Si, Ti, Zn, Cr, and/or Zr as described above.

[0061] To prepare a metal product for use as a current collector, the metal product may be subjected to one or more treatment processes to form a coating layer over at least a portion of one or more surfaces of the metal product, where molecules of the coating layer are covalently bonded to the surface. The coating layer may be organic, inorganic, or polymeric and provide the enhancements described above (e.g., corrosion resistance, conductivity, adhesion improvement) for use of the metal product as a current collector. The coating layer may be generated by way of a reactive coating process in which a reactive solution is contacted with the surface of the substrate and molecules in the reactive solution can react with and become covalently bonded to the surface. Example reactive solutions may comprise, for example, solutions including reactive compounds such as phosphorous acids, phosphoric acids, phosphonic acids, silanes, acrylic acids, or metal hydrides, among others. These reactive compounds may be functionalized with one or more polymeric groups, polymeric precursor groups, organic groups, inorganic groups, metals, or the like.

[0062] Specific example reactive compounds may include multifunctional molecules (e.g., bifunctional molecules or trifunctional molecules), such as including a first functional group for covalently bonding to the surface of the metal product and a second functional group, and optionally further functional groups. The first functional group in the reactive compound may, for example, comprise a hydroxyl substituted group, such as a hydroxyl substituted silicon group (e.g., -Si-OH), a hydroxyl substituted phosphorous group (e.g., -P- OH), a hydrogen substituted silicon group (e.g., -Si-H), or a hydrogen substituted phosphorous group (e.g., -P-H) where the silicon and phosphorous groups may include one or more additional substituents, one or more of which may correspond to the second functional group and, optionally, one or more of which may provide additional covalent bonding character (e.g., additional hydroxyl or hydrogen substituted groups). For example, the hydroxyl groups or the hydride groups of the phosphorous or silicon compounds may react at the surface of the metal product, such as directly with metal atoms of the metal product or with oxygen atoms of an oxide surface layer of the metal product, to form a metal- phosphorous or metal-silicon bond or a metal-oxygen-phosphorous or metal-oxygen-silicon bond. Upon bonding with the metal product, the first functional group may comprise a P-0 group or Si-0 group, for example. In some cases, example reactive compounds may include multiple hydroxyl substituted groups and/or multiple hydrogen substituted groups.

[0063] The second functional group may provide additional functionality to the metal product to improve operation as a current collector. For example, the second functional group may comprise an adhesion promoter group or a corrosion inhibitor group. Optionally, the second functional group may comprise a hydrophobic group or a nonpolar group, which may be useful for promoting adhesion between the coating layer and an overlayer, such as an active material layer or a conductive layer. Optionally, the second functional group comprises one or more R groups, such as a substituted, unsubstituted, saturated, or unsaturated aliphatic group or a substituted or unsubstituted aromatic group. Example reactive compounds may include alkyl phosphonic acids, alkyl silanes, alkyl silanols, alkyl phosphates, alkenyl phosphonic acids, alkenyl silanes, alkenyl silanols, alkenyl phosphates, or the like. The second functional group may be useful for inhibiting reaction of the metal product with HF, such as by functioning as a barrier layer or by functioning as a sacrificial material that may react more readily with HF than aluminum does.

[0064] In embodiments, one or more additional functional groups may provide additional properties to the reactive compounds and may optionally provide the same properties as the first functional group or the second functional group. For example, in some embodiments, the first functional group may correspond to a first hydroxyl or hydrogen substituted group, the second functional group may correspond to a first R group, and a third functional group corresponds to a second hydroxyl or hydrogen substituted group. In some other embodiments, the third functional group corresponds to a second R group.

[0065] The coating layer may have any suitable thickness, which may optionally be a function of the composition of the reactive compound, for example. In some embodiments, a thickness of the coating layer may be from about 1 nm to about 1 pm. Example thicknesses for the coating layer may be from 1 nm to 5 nm, from 1 nm to 10 nm, from 1 nm to 50 nm, from 1 nm to 100 nm, from 1 nm to 500 nm, from 1 nm to 1 pm, from 5 nm to 10 nm, from 5 nm to 50 nm, from 5 nm to 100 nm, from 5 nm to 500 nm, from 5 nm to 1 pm, from 10 nm to 50 nm, from 10 nm to 100 nm, from 10 nm to 500 nm, from 10 nm to 1 pm, from 50 nm to 100 nm, from 50 nm to 500 nm, from 50 nm to 1 pm, from 100 nm to 500 nm, from 100 nm to 1 pm, or from 500 nm to 1 pm. Optionally, the coating layer may comprise a monolayer, such as a monolayer of molecules covalently bonded to the surface of the current collector. Optionally, the coating layer may comprise a multilayer.

[0066] In some embodiments, the metal product may be subjected to an immersion coating process or other wet coating process to form the covalently bonded coating layer. FIG. 2 provides a schematic illustration of an immersion coating process of a metal product 200 as it travels along direction 205 past rollers 210. Metal product 200 may, for example, correspond to a flexible metal product, such as sheet metal or metal foil comprising aluminum or copper, useful as a current collector in a battery cell. Metal product 200 is immersed in bath 215, which may comprise a reactive solution including a reactive compound, as described above. While a surface of the metal product 200 is in contact with the bath 215, reactions between the reactive compound and the surface may take place, resulting in molecules of the reactive compound becoming covalently bonded with the surface. In some cases, by-products may be formed during the reaction, such as water or hydrogen gas, for example. Upon exit from bath 215, metal product 200 may have one or more surfaces coated with a covalently bonded coating. The amount of time the metal product is exposed to the reactive solution, the concentration of the reactive compound, the presence and concentration of other components in the reactive solution, the speed of the metal product as it travels along direction 205, and other process conditions, such as temperature, pressure, or the like, may be adjusted and used for optimizing the reaction conditions to form a suitable covalently bonded layer over the surfaces of the metal product 200.

[0067] The immersion coating process depicted in FIG. 2 is merely one example of a useful technique for forming a covalently bonded coating layer over the surface of a metal product, and it will be appreciated that other coating techniques may be employed, such as spray coating techniques, roll-to-roll coating techniques, dip coating techniques, spin coating techniques, or the like. In some cases, the covalently bonded coating layer may be generated by exposing the metal product to a reactive compound in the gas phase. Other deposition techniques may be useful for forming a covalently bonded coating layer over the surface of a metal product, including vacuum deposition, sputtering, plasma deposition, flame pyrolysis deposition, or the like.

[0068] For use as a battery component, the current collector with a covalently bonded coating layer may have other materials deposited over the coating layer. FIG. 3 provides an overview of making various battery components. Initially, a current collector 300 may be provided. Current collector 300 may be a metal foil or sheet metal current collector, as described above. Current collector 300 may comprise aluminum, an aluminum alloy, copper, or a copper alloy, for example. Current collector 300 may be subjected to a reactive coating process to form a coating layer 305 over a surface of current collector, such as where molecules of the coating layer are covalently bonded to the surface of the current collector during the reactive coating process, as described above. Current collector 300 with coating layer 305 may be useful as a current collector in a variety of battery systems and may be suitable for an anode current collector or a cathode current collector, depending on the composition and battery chemistry.

[0069] The current collector 300 and coating layer 305 may be subjected to another coating process to form additional layers over the coating layer 305. Generally, for use in battery applications, an electrode active material layer 315 may be formed above the coating layer 305. Electrode active material layer 315 may comprise an active material of a battery electrode that is oxidized or reduced during charging or discharging of a battery. Example active materials may include lithium ion cathode active materials, such as lithium cobalt oxide, lithium iron phosphate, or lithium manganese oxide, or lithium ion anode active materials, such as graphite and other carbon structures, such as graphene, carbon nanotubes, carbon nanohoms, nanowires, fullerenes, and mixtures thereof in any suitable ratio. In some battery systems, a metallic anode may be used, such as a lithium anode in a lithium battery. Optionally, electrode active material layer 315 may comprise a binder, which may be conductive or nonconductive, but may be present to provide for adhesion between the active material of the electrode active material layer 315 and underlying conductive layer 310 or current collector 300 or covalently bonded coating layer 305. [0070] Optionally, a conductive layer 310 may first be coated over coating layer 305 by subjecting the current collector 300 and coating layer 305 to a coating process, such as prior to coating the electrode active material layer 315. Example materials for conductive layer 310 may comprise, for example, conductive carbonaceous layers, such as conductive carbon or graphite. Optionally, a conductive layer 310 may comprise a binder, which may be conductive or nonconductive, but may be present to provide for adhesion between conductive material of the conductive layer 310 and the electrode active material layer 315.

[0071] As noted above, the presence of the covalently bonded coating layer 305 may also provide for improved adhesion, conductivity, or contact resistance between the electrode active material layer 315 and the current collector 300, and so the amount of binder used in an optional conductive layer 310 and/or in electrode active material layer 315 may be reduced in the battery components and battery systems described herein as compared to a battery component or battery system lacking a covalently bonded coating. A reduction in the amount of binder used in electrode active material layer 315 may provide for an increase in the amount or relative amount of active material in electrode active material layer 315 and a corresponding increase or relative increase in capacity (e.g., increased specific capacity). [0072] Electrode active material layer 315 and optional conductive layer 310 may be coated over current collector 300 and covalently bonded coating layer 305 using any suitable means. FIG. 4 provides a schematic illustration of roll-coating of a substrate 400 as it travels along direction 405 and past rollers 410. Substrate 400 may comprise one or more coatings already deposited on one or more surfaces, such as a covalently bonded coating layer as described above. One or more of rollers 410 may be at least partially immersed in mixture 415 for transferring onto substrate 400, such as by one or more roll-to-roll transfer processes. For example, substrate 400 may correspond to an aluminum foil coated with a covalently bonded coating layer and mixture 415 may correspond to a slurry including one or more of an electrode active material, a conductive material, or a binder material. The slurry may include an evaporable solvent that is evaporated, such as in a subsequent drying process after the coating process. Via the coating process, the coated material may be deposited onto a surface of the substrate 400 to form a battery component, such as an electrode, and used in assembly of a battery cell, for example. Optionally mixture 415 may correspond to a reactive solution, as described above, and used to form a covalently bonded coating layer over one or more surfaces of substrate 400. For example, such a coating layer may be generated by way of a reactive coating process in which a reactive solution is contacted with the surface of the substrate and molecules in the reactive solution can react with and become covalently bonded to the surface.

[0073] The following examples will serve to further illustrate the present invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the invention. During the studies described in the following examples, conventional procedures were followed, unless otherwise stated. Some of the procedures are described below for illustrative purposes.

EXAMPLE 1 - Lithium Ion battery with Treated Aluminum Foil Cathode Current Collector [0074] FIG. 5 provides a schematic overview of an example battery cell 500. Battery cell 500 is different from battery cell 100 illustrated in FIG. 1 in at least that battery cell 500 includes first covalently bonded coating layer 510 in addition to first current collector 505, first active material layer 515, separator 520, electrolyte 525, second active material layer 530, and second current collector 535. Optionally, a second covalently bonded coating layer (not shown) may be positioned between second current collector 535 and second active material layer.

[0075] First active material layer 515 may comprise a cathode of battery cell 500 and second active material layer 530 may comprise an anode of battery cell 500. Here, first active material layer 515 comprises LiCoCh, but other active material layers may be used. Optionally, first active material layer 515 comprises a conductive additive (e.g., conductive carbon or a conductive polymer) and/or a binder (e.g., a conductive polymer). First current collector 505 comprises a foil of an aluminum alloy. Second active material layer 530 comprises graphite and optionally a binder, but other active material layers may be used. Second current collector 535 comprises a copper foil. Separator 520 may, for example, comprise a non-electrically-conductive porous material, such as a porous polymeric material, such as a porous polypropylene or polyethylene membrane. Electrolyte 525 may comprise a lithium salt dissolved in an organic solvent, such as about 1 M LiPFe in ethylene carbonate and/or propylene carbonate. In this example, first covalently bonded coating layer 510 comprises a silane derivative as a corrosion inhibitor, formed by exposing the first current collector 505 to trimethylsilanol. Identification of the above described materials as example components of battery cell 500 is not intended to be limiting, and other known active material layer components, covalently bonded coating materials, separator materials, and electrolyte components may be used in battery cell 500.

ILLUSTRATIVE ASPECTS

[0076] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4 ”).

[0077] Aspect 1 is an energy storage device component, comprising: a current collector, wherein the current collector has a surface; and a coating layer disposed over the surface of the current collector, wherein molecules of the coating layer are covalently bonded to the surface of the current collector.

[0078] Aspect 2 is the energy storage device component of any previous or subsequent aspect, wherein the current collector comprises a metal foil.

[0079] Aspect 3 is the energy storage device component of any previous or subsequent aspect, wherein the current collector comprises an aluminum alloy or a copper alloy.

[0080] Aspect 4 is the energy storage device component of any previous or subsequent aspect, wherein the current collector has a thickness of from 0.005 mm to 0.05 mm.

[0081] Aspect 5 is the energy storage device component of any previous or subsequent aspect, wherein the coating layer comprises multifunctional molecules including a first functional group for covalently bonding to the current collector and a second functional group.

[0082] Aspect 6 is the energy storage device component of any previous or subsequent aspect, wherein the first functional group comprises a hydroxyl substituted silicon, a hydroxyl substituted phosphorous, a hydrogen substituted silicon, or a hydrogen substituted phosphorous.

[0083] Aspect 7 is the energy storage device component of any previous or subsequent aspect, wherein the second functional group comprises an adhesion promoter group, a corrosion inhibitor group, or a conductivity promoter group.

[0084] Aspect 8 is the energy storage device component of any previous or subsequent aspect, wherein the second functional group comprises a hydrophobic group or a nonpolar group.

[0085] Aspect 9 is the energy storage device component of any previous or subsequent aspect, wherein the second functional group comprises one or more R groups, wherein R is a substituted or unsubstituted, saturated or unsaturated aliphatic group or a substituted or unsubstituted aromatic group.

[0086] Aspect 10 is the energy storage device component of any previous or subsequent aspect, wherein R is a polymeric group, a polymeric precursor group, an inorganic acidic group, an inorganic basic group, an inorganic neutral group, or an ion coordination group.

[0087] Aspect 11 is the energy storage device component of any previous or subsequent aspect, wherein the multifunctional molecule comprises a substituted silane, a substituted silanol, a substituted phosphate or phosphate ester, a substituted phosphonate, or a phosphoric acid.

[0088] Aspect 12 is the energy storage device component of any previous or subsequent aspect, wherein the coating layer has a thickness of from 1 nm to 1 pm.

[0089] Aspect 13 is the energy storage device component of any previous or subsequent aspect, wherein the coating layer comprises a monolayer.

[0090] Aspect 14 is the energy storage device component of any previous or subsequent aspect, further comprising an electrode active material layer disposed over the coating layer. [0091] Aspect 15 is the energy storage device component of any previous or subsequent aspect, wherein the electrode active material layer comprises one or more of an electrode active material, a conductive additive, or a binder.

[0092] Aspect 16 is the energy storage device component of any previous or subsequent aspect, wherein the electrode active material layer has a thickness of from 1 pm to 50 mm.

[0093] Aspect 17 is the energy storage device component of any previous or subsequent aspect, further comprising a conductive layer between the coating layer and the electrode active material layer, wherein the conductive layer comprises one or more of a carbonaceous material or a binder.

[0094] Aspect 18 is the energy storage device component of any previous or subsequent aspect, wherein the conductive layer has a thickness of from 10 nm to 2 mm.

[0095] Aspect 19 is the energy storage device component of any previous or subsequent aspect, further comprising a second electrode active layer, an electrolyte, and a separator, wherein the electrolyte and the separator are positioned between the first electrode active layer and the second electrode active layer.

[0096] Aspect 20 is a method of making an energy storage device component, the method comprising: providing a current collector, wherein the current collector has a surface; and subjecting the surface of the current collector to a reactive coating process to generate a coating layer over the surface of the current collector, wherein molecules of the coating layer are covalently bonded to the surface of the current collector during the reactive coating process.

[0097] Aspect 21 is the method of any previous or subsequent aspect, further comprising: subjecting the current collector and the coating layer to a coating process to form an electrode active material layer over the coating layer.

[0098] Aspect 22 is the method of any previous or subsequent aspect, further comprising: subjecting the current collector and the coating layer to a coating process to form a conductive layer over the coating layer, wherein the conductive layer comprises one or more of a carbonaceous material or a binder.

[0099] Aspect 23 is the method of any previous or subsequent aspect, further comprising: subjecting the current collector, the coating layer, and the conductive layer to another coating process to form an electrode active material layer over the conductive layer.

[0100] Aspect 24 is the method of any previous or subsequent aspect, wherein one or more coating processes comprise immersion coating processes, roll-to-roll coating processes, spray coating processes, or vacuum deposition processes.

[0101] Aspect 25 is the method of any previous or subsequent aspect, wherein the energy storage device component is the energy storage device component of any of any previous or subsequent aspect.

[0102] Aspect 26 is the energy storage device component of any of any previous or subsequent aspect, made using the method of any of any previous or subsequent aspect. [0103] All patents, publications and abstracts cited above are incorporated herein by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed.

Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

26 WHAT IS CLAIMED IS:

1. An energy storage device component, comprising: a current collector, wherein the current collector has a surface; and a coating layer disposed over the surface of the current collector, wherein molecules of the coating layer are covalently bonded to the surface of the current collector.

2. The energy storage device component of claim 1, wherein the current collector comprises a metal foil.

3. The energy storage device component of claim 1, wherein the current collector comprises an aluminum alloy or a copper alloy.

4. The energy storage device component of claim 1, wherein the current collector has a thickness of from 0.005 mm to 0.05 mm.

5. The energy storage device component of claim 1, wherein the coating layer comprises multifunctional molecules including a first functional group for covalently bonding to the current collector and a second functional group.

6. The energy storage device component of claim 5, wherein the first functional group comprises a hydroxyl substituted silicon, a hydroxyl substituted phosphorous, a hydrogen substituted silicon, or a hydrogen substituted phosphorous.

7. The energy storage device component of claim 5, wherein the second functional group comprises an adhesion promoter group, a corrosion inhibitor group, or a conductivity promoter group.

8. The energy storage device component of claim 5, wherein the second functional group comprises a hydrophobic group or a nonpolar group.

9. The energy storage device component of claim 5, wherein the second functional group comprises one or more R groups, wherein R is a substituted or unsubstituted, saturated or unsaturated aliphatic group or a substituted or unsubstituted aromatic group.

10. The energy storage device component of claim 9, wherein R is a polymeric group, a polymeric precursor group, an inorganic acidic group, an inorganic basic group, an inorganic neutral group, or an ion coordination group.

11. The energy storage device component of claim 5, wherein the multifunctional molecule comprises a substituted silane, a substituted silanol, a substituted phosphate or phosphate ester, a substituted phosphonate, or a phosphoric acid.

12. The energy storage device component of claim 1, wherein the coating layer has a thickness of from 1 nm to 1 pm.

13. The energy storage device component of claim 1, wherein the coating layer comprises a monolayer.

14. The energy storage device component of claim 1, further comprising an electrode active material layer disposed over the coating layer.

15. The energy storage device component of claim 14, wherein the electrode active material layer comprises one or more of an electrode active material, a conductive additive, or a binder.

16. The energy storage device component of claim 14, wherein the electrode active material layer has a thickness of from 1 pm to 50 mm.

17. The energy storage device component of claim 14, further comprising a conductive layer between the coating layer and the electrode active material layer, wherein the conductive layer comprises one or more of a carbonaceous material or a binder.

18. The energy storage device component of claim 17, wherein the conductive layer has a thickness of from 10 nm to 2 mm.

19. The energy storage device component of claim 14, further comprising a second electrode active layer, an electrolyte, and a separator, wherein the electrolyte and the separator are positioned between the first electrode active layer and the second electrode active layer.

20. A method of making an energy storage device component, the method comprising: providing a current collector, wherein the current collector has a surface; and subjecting the surface of the current collector to a reactive coating process to generate a coating layer over the surface of the current collector, wherein molecules of the coating layer are covalently bonded to the surface of the current collector during the reactive coating process.

21. The method of claim 20, further comprising: subjecting the current collector and the coating layer to a coating process to form an electrode active material layer over the coating layer.

22. The method of claim 20, further comprising: subjecting the current collector and the coating layer to a coating process to form a conductive layer over the coating layer, wherein the conductive layer comprises one or more of a carbonaceous material or a binder.

23. The method of claim 22, further comprising: subjecting the current collector, the coating layer, and the conductive layer to another coating process to form an electrode active material layer over the conductive layer.

24. The method of claim 20, wherein one or more coating processes comprise immersion coating processes, roll-to-roll coating processes, spray coating processes, or vacuum deposition processes.

25. The method of claim 20, wherein the energy storage device component is the energy storage device component of any of claims 1-19.

26. The energy storage device component of any of claims 1-19, made using the method of any of claims 20-24.