Lithium anode device stack manufacturing

Patent metadata

Field	Value
Publication number	US-2024145763-A1
Application number	US-202318541430-A
Country	US
Kind code	A1
Filing date	Dec 15, 2023
Priority date	Sep 21, 2017
Publication date	May 2, 2024
Grant date	—

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

1 . An anode electrode structure, comprising:
a current collector comprising copper; a silicon graphite anode formed on the current collector; a lithium metal film formed on the silicon graphite anode; and a protective film formed on the lithium 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.

2 . The anode electrode structure of claim 1 , 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.

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

4 . The anode electrode structure of claim 3 , wherein the current collector has a thickness in a range from about 2 micrometers to about 8 micrometers.

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

6 . 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.

7 . 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.

8 . The anode electrode structure of claim 7 , wherein the copper film has a thickness in a range from about 5 nanometers to about 40 nanometers.

9 . The anode electrode structure of claim 7 , wherein the copper film has a thickness in a range from about 10 nanometers to about 20 nanometers.

10 . The anode electrode structure of claim 7 , 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.

11 . The anode electrode structure of claim 7 , wherein the lithium metal film has a thickness in a range from about 1 micrometer to about 20 micrometers.

12 . The anode electrode structure of claim 7 , wherein the current collector has a thickness in a range from about 2 micrometers to about 8 micrometers.

13 . The anode electrode structure of claim 7 , wherein the protective film further comprises a metal film.

14 . The anode electrode structure of claim 13 , wherein the metal film is a bismuth film.

15 . 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.

16 . The anode electrode structure of claim 15 , wherein the copper film has a thickness in a range from about 5 nanometers to about 40 nanometers.

17 . The anode electrode structure of claim 15 , 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 15 , 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 15 , 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 15 , 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