Method of forming an anode structure with dielectric coating

Patent metadata

Field	Value
Publication number	US-12057574-B2
Application number	US-202318315240-A
Country	US
Kind code	B2
Filing date	May 10, 2023
Priority date	Jan 9, 2015
Publication date	Aug 6, 2024
Grant date	Aug 6, 2024

Abstract

The present disclosure generally relate to separators, high performance electrochemical devices, such as, batteries and capacitors, including the aforementioned separators, and methods for fabricating the same. In one implementation, a separator for a battery is provided. The separator comprises a substrate capable of conducting ions and at least one dielectric layer capable of conducting ions. The at least one dielectric layer at least partially covers the substrate and has a thickness of 1 nanometer to 2,000 nanometers.

First claim

The invention claimed is:

1. An anode electrode structure, comprising:
an anode containing at least one of lithium metal, lithium-alloy, or a mixture of lithium metal and lithium alloy; and
at least one dielectric layer capable of conducting ions, wherein the at least one dielectric layer at least partially covers a surface of the anode and has a thickness of 1 nanometer to 2,000 nanometers,
wherein the at least one dielectric layer comprises a plurality of dielectric columnar projections and a nano-porous structure formed between the dielectric columnar projections.

2. The anode electrode structure of claim 1 , wherein the at least one dielectric layer comprises a ceramic material.

3. The anode electrode structure of claim 2 , wherein the ceramic material comprises porous boron nitride, aluminum oxide, porous aluminum oxide, porous-ZrO 2 , porous-SiO 2 , porous-MgO, porous-TiO 2 , porous-Ta 2 O 5 , porous-Nb 2 O 5 , porous-LiAlO 2 , porous-BaTiO 3 , ion-conducting garnet, ion-conducting perovskites, ion-conducting anti-perovskites, porous glass dielectric, or combinations thereof.

4. The anode electrode structure of claim 3 , wherein the ceramic material is a porous aluminum oxide.

5. The anode electrode structure of claim 4 , wherein the porous aluminum oxide further comprises zirconium oxide, silicon oxide, or combinations thereof.

6. The anode electrode structure of claim 1 , wherein the anode further contains materials selected from the group consisting of: carbon, nickel, copper, tin, indium, silicon, and combinations thereof.

7. The anode electrode structure of claim 1 , wherein the at least one dielectric layer is a binder-free dielectric layer.

8. The anode electrode structure of claim 1 , wherein the nano-porous structure comprises a plurality of no-pores comprising an average pore size of less than about 10 nanometers.

9. An anode electrode structure, comprising:
an anode containing at least one of lithium metal, lithium-alloy, or a mixture of lithium metal and lithium alloy; and
at least one dielectric layer comprising a porous aluminum oxide, wherein the at least one dielectric layer at least partially covers a surface of the anode and has a thickness of 1 nanometer to 2,000 nanometers,
wherein the at least one dielectric layer further comprises a plurality of dielectric columnar projections and a nano-porous structure formed between the dielectric columnar projections.

10. The anode electrode structure of claim 9 , wherein the anode further contains materials selected from the group consisting of: carbon, nickel, copper, tin, indium, silicon, and combinations thereof.

11. The anode electrode structure of claim 9 , wherein the at least one dielectric layer is a binder-free dielectric layer.

12. The anode electrode structure of claim 9 , wherein the at least one dielectric layer has a thickness in a range of 10 nanometer to 600 nanometers.

13. The anode electrode structure of claim 9 , wherein the at least one dielectric layer comprises from about 50 wt % to about 100 wt % of aluminum oxide based on the total weight of the at least one dielectric layer.

14. The anode electrode structure of claim 13 , wherein the at least one dielectric layer comprises from about 75 wt % to about 100 wt % of aluminum oxide based on the total weight of the at least one dielectric layer.

15. The anode electrode structure of claim 14 , wherein the at least one dielectric layer comprises from about 85 wt % to about 100 wt % of aluminum oxide based on the total weight of the at least one dielectric layer.

16. The anode electrode structure of claim 9 , wherein the at least one dielectric layer further comprises SiO 2 .

17. An anode electrode structure, comprising:
an anode containing at least one of lithium metal, lithium-alloy, or a mixture of lithium metal and lithium alloy; and
at least one dielectric layer comprising a porous aluminum oxide, wherein the at least one dielectric layer at least partially covers a surface of the anode and has a thickness of 1 nanometer to 2,000 nanometers,
wherein the at least one dielectric layer further comprises a plurality of dielectric columnar projections and a nano-porous structure formed between the columnar projections of dielectric material, the nano-porous structure comprising a plurality of nano-pores having a diameter of about 1 nanometer to about 20 nanometers.

18. The anode electrode structure of claim 17 , wherein the a plurality of nano-pores has an average pore size of less than about 10 nanometers.

19. The anode electrode structure of claim 17 , wherein the plurality of nano-pores has a diameter of about 1 nanometer to about 10 nanometers.

Assignees

• Applied Materials Inc

Inventors

• Herle Subramanya P

Classifications

• H01M50/451

  comprising layers of only organic material and layers containing inorganic material · CPC title

• H01M4/405

  Alloys based on lithium · CPC title

• H01M50/489

  Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties · CPC title

• H01M50/434

  Ceramics · CPC title

• H01M50/437

  Glass · CPC title