Three-dimensional lattice batteries via additive manufacturing

Patent metadata

Field	Value
Publication number	US-11817588-B2
Application number	US-201916593622-A
Country	US
Kind code	B2
Filing date	Oct 4, 2019
Priority date	Oct 4, 2018
Publication date	Nov 14, 2023
Grant date	Nov 14, 2023

Abstract

Provided here is a method of manufacturing a lattice electrode useful in an energy storage device such as a battery or capacitor. A lattice electrode useful in an energy storage device such as a battery or capacitor also is provided, along with energy storage devices such as batteries or capacitors.

First claim

What is claimed is:

1. An electrode incorporated within an electrochemical cell, the electrochemical cell comprising:
the electrode;
a cathode;
a polymeric permeable membrane; and
a liquid electrolyte,
wherein the electrode comprises: a three-dimensional open cell lattice comprising a plurality of unit cells defined by a plurality of porous, interconnected, conductive metal[,] or ceramic trusses formed by droplet-based printing having a diameter ranging from 20 μm to 50 μm, periodically-spaced with periodicity ranging from 2 μm to 500 μm per unit cell in an X-dimension, a Y-dimension, and/or a Z-dimension,
wherein the electrode comprises a thickness from about 250 μm to about 450 μm,
wherein the cathode comprises lithium oxide, lithium cobalt oxide, lithium manganese oxide, lithium titanium oxide, lithium nickel oxide, lithium iron phosphate fluoride, lithium cobalt nickel manganese oxide, lithium cobalt nickel manganese oxide, silicon, lithium ferrophosphate, sulfur, a lithium foil, or combinations thereof,
wherein the polymeric permeable separator comprises polyolefin, polyethylene, polypropylene, or combinations thereof, and
wherein the liquid electrolyte comprises ethylene carbonate, propylene carbonate, ethyl methyl carbonate, or a combination thereof and further comprises LiPF 6 , LiAsF 6 , LiClO 4 , LiBF 4 , lithium triflate, or combinations thereof.

2. The electrode of claim 1 , wherein the lattice comprises from 10 to 100,000 repeated cells in at least one dimension.

3. The electrode of claim 1 , wherein the conductive metal comprises lithium, sodium, aluminum, magnesium, silicon, zinc, silver, tin, antimony, bismuth, gold, or alloys of any of the preceding, or combinations of any of the preceding.

4. The electrode of claim 1 , wherein the truss is a rod, a cylinder, a column, a scutoid, a cylindroid, a conical shape, a polyhedron, a sphere, a spheroid, an ovoid, a spiral, or a helix.

5. The electrode of claim 1 , wherein the porosity of the trusses is greater than 1%.

6. The electrode of claim 5 , wherein the trusses are sintered metal.

7. The electrode of claim 6 , wherein sintered metal is silver.

8. The electrode of claim 1 , comprising at least 1 Mode of deformation as determined by M=−3j+b+6, where M represents the number of modes, j represents the number of frictionless joints, and b is the number of links,
wherein the electrode has a specific capacity in a lithium ion electrochemical cell after 30 charge and discharge cycles that is at least 50% greater than a solid electrode of the same material, and/or having an area-normalized specific capacity measured in a lithium ion electrochemical cell under different C-rates of 0.1C, 0.2C, and 0.5C, and twice at 1C for a total of 40 cycles that is at least 50% greater than a solid electrode of the same material.

9. An electrochemical cell comprising an anode, a cathode, a separation membrane, and an electrolyte contained within a housing, wherein the anode comprises the electrode of claim 1 .

10. The electrode of claim 1 , wherein the liquid electrolyte comprises a combination of ethylene carbonate, propylene carbonate, and ethyl methyl carbonate and further comprises LiFP 6 .

11. A battery or capacitor comprising the electrode of claim 1 .

12. The electrode of claim 1 , wherein the component is at least partially coated with an electrically active material.

13. The electrode of claim 1 , wherein the cells are polyhedral, such as octahedral, tetrahedral, cubic, cuboid, rhomboid, spherical, spheroid, or combinations thereof.

14. The electrode of claim 1 , wherein the periodicity ranges from 100 μm to 300 μm per unit cell in an X-dimension, a Y-dimension, and/or a Z-dimension.

15. The electrode of claim 1 , wherein the polymeric permeable separator comprises a combination of polyethylene and polypropylene.

16. The electrode of claim 1 , wherein the electrode comprises a solid-phase volume fraction (VF) of from 0.2 to 0.6.

Assignees

• Univ Carnegie Mellon
• Univ Missouri

Inventors

• Panat Rahul
• Li Jie
• Park Jonghyun
• Saleh Mohammad Sadeq

Classifications

• H01M4/80 Primary

  Porous plates, e.g. sintered carriers · CPC title

• H01G11/26

  characterised by their structure, e.g. multi-layered, porosity or surface features · CPC title

• H01G11/56

  Solid electrolytes, e.g. gels; Additives therein · CPC title

• H01G11/70

  characterised by their structure · CPC title

• H01M4/38

  of elements or alloys · CPC title