Lithium anode device stack manufacturing

Patent metadata

Field	Value
Publication number	US-11888109-B2
Application number	US-202217964369-A
Country	US
Kind code	B2
Filing date	Oct 12, 2022
Priority date	Sep 21, 2017
Publication date	Jan 30, 2024
Grant date	Jan 30, 2024

Abstract

Metal electrodes, more specifically lithium-containing anodes, high performance electrochemical devices, such as secondary batteries, including the aforementioned lithium-containing electrodes, and methods for fabricating the same are provided. In one or more embodiments, an anode electrode structure is provided and includes a current collector comprising copper, a lithium metal film formed on the current collector, a copper film formed on the lithium metal film, and a protective film formed on the copper film. The protective film is a lithium-ion conducting film can include lithium-ion conducting ceramic, a lithium-ion conducting glass, or ion conducting liquid crystal.

First claim

The invention claimed is:

1. An anode electrode structure, comprising:
a current collector comprising copper;
a lithium metal film formed on the current collector;
a metal film formed on the lithium metal film and in direct contact with the current collector; and
a protective film formed on the metal film,
wherein the protective film is a lithium-ion conducting film comprising lithium-ion conducting ceramic, lithium-ion conducting glass, lithium-ion conducting polymer, lithium- ion conducting liquid crystal, or combinations thereof, and
wherein the metal film is selected from a copper film, a bismuth film, or combinations thereof.

2. The anode electrode structure of claim 1 , wherein the metal film has a thickness in a range from about 5 nanometers to about 40 nanometers.

3. The anode electrode structure of claim 2 , wherein the metal film comprises copper and has a thickness in a range from about 10 nanometers to about 20 nanometers.

4. The anode electrode structure of claim 2 , wherein the lithium-ion conducting film comprises one or more of aluminum oxide, LiPON, Li 7 La 3 Zr 2 O 12 (LLZO), Li 2 S—P 2 S 5 , Li 10 GeP 2 S 12 , Li 3 PS 4 , (1-x)LiI-(x)Li 4 SnS 4 , (x)LiI-(1-x)Li 4 SnS 4 , (1-x)LiI-(x)Li 4 SnS 4 , (x)LiI-(1-x)Li 4 SnS 4 ), wherein 0<x<1.

5. The anode electrode structure of claim 2 , wherein the lithium metal film has a thickness in a range from about 1 micrometer to about 20 micrometers.

6. The anode electrode structure of claim 5 , wherein the current collector has a thickness in a range from about 2 micrometers to about 8 micrometers.

7. The anode electrode structure of claim 1 , wherein the current collector comprises:
a first nickel or chromium containing film;
a second copper film formed on the first nickel or chromium containing film and having a thickness in a range from about 50 nanometers to about 500 nanometers; and
a second nickel or chromium containing film formed on the second copper film and having a thickness in a range from about 20 nanometers to about 50 nanometers.

8. The anode electrode structure of claim 1 , wherein the current collector comprises:
a polyethylene terephthalate (PET) polymer substrate; and
a second copper film formed on the PET polymer substrate.

9. An anode electrode structure, comprising:
a current collector comprising copper;
a lithium metal film formed on the current collector;
a copper film formed on the lithium metal film and in direct contact with the current collector; and
a protective film formed on the copper film,
wherein the protective film is a lithium-ion conducting film comprising lithium-ion conducting ceramic, lithium-ion conducting glass, lithium-ion conducting polymer, lithium- ion conducting liquid crystal, or combinations thereof.

10. The anode electrode structure of claim 9 , wherein the copper film has a thickness in a range from about 5 nanometers to about 40 nanometers.

11. The anode electrode structure of claim 9 , wherein the copper film has a thickness in a range from about 10 nanometers to about 20 nanometers.

12. The anode electrode structure of claim 9 , wherein the lithium-ion conducting film comprises one or more of aluminum oxide, LiPON, Li 7 La 3 Zr 2 O 12 (LLZO), Li 2 S—P 2 S 5 , Li 10 GeP 2 S 12 , Li 3 PS 4 , (1-x)LiI-(x)Li 4 SnS 4 , (x)LiI-(1-x)Li 4 SnS 4 , (1-x)LiI— (x)Li 4 SnS 4 , (x)LiI-(1-x)Li 4 SnS 4 ), wherein 0<x<1.

13. The anode electrode structure of claim 9 , wherein the lithium metal film has a thickness in a range from about 1 micrometer to about 20 micrometers.

14. The anode electrode structure of claim 9 , wherein the current collector has a thickness in a range from about 2 micrometers to about 8 micrometers.

15. The anode electrode structure of claim 1 , wherein the metal film is a bismuth film.

16. An anode electrode structure, comprising:
a current collector comprising copper;
a lithium metal film formed on the current collector;
a copper film formed on the lithium metal film, in direct contact with the current collector, and having a thickness in a range from about 5 nanometers to about 40 nanometers; and
a protective film formed on the copper film;
wherein the protective film is a lithium-ion conducting film comprising lithium-ion conducting ceramic, lithium-ion conducting glass, lithium-ion conducting polymer, lithium- ion conducting liquid crystal, or combinations thereof; and
wherein the lithium-ion conducting film comprises one or more of aluminum oxide, LiPON, Li 7 La 3 Zr 2 O 12 (LLZO), Li 2 S-P 2 S 5 , Li 10 GeP 2 S 12 , Li 3 PS 4 , (1-x)LiI-(x)Li 4 SnS 4 , (x)LiI- (1-x)Li 4 SnS 4 , (1-x)LiI-(x)Li 4 SnS 4 , (x)LiI-(1-x)Li 4 SnS 4 ), wherein 0<x<1.

17. The anode electrode structure of claim 16 , wherein the copper film has a thickness in a range from about 10 nanometers to about 20 nanometers.

18. The anode electrode structure of claim 16 , wherein the lithium-ion conducting film comprises one or more of (1-x)LiI-(x)Li 4 SnS 4 , (x)LiI-(1-x)Li 4 SnS 4 , (1-x)LiI-(x)Li 4 SnS 4 , (x)LiI-(1-x)Li 4 SnS 4 ), wherein 0<x<1.

19. The anode electrode structure of claim 16 , wherein the lithium metal film has a thickness in a range from about 1 micrometer to about 20 micrometers.

20. The anode electrode structure of claim 16 , wherein the current collector has a thickness in a range from about 2 micrometers to about 8 micrometers.

Assignees

• Applied Materials Inc

Inventors

• Herle Subramanya P

Classifications

• H01M2004/027

  Negative electrodes · CPC title

• H01M10/0525 Primary

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M4/134 Primary

  Electrodes based on metals, Si or alloys · CPC title

• H01M4/133

  Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx · CPC title

• H01M4/587

  for inserting or intercalating light metals · CPC title