Manufacturing of high capacity prismatic lithium-ion alloy anodes

Patent metadata

Field	Value
Publication number	US-9761882-B2
Application number	US-201715443821-A
Country	US
Kind code	B2
Filing date	Feb 27, 2017
Priority date	Feb 28, 2011
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

High capacity energy storage devices and energy storage device components, and more specifically, to a system and method for fabricating such high capacity energy storage devices and storage device components using processes that form three-dimensional porous structures are provided. In one embodiment, an anode structure for use in a high capacity energy storage device, comprising a conductive collector substrate, a three-dimensional copper-tin-iron porous conductive matrix formed on one or more surfaces of the conductive collector substrate, comprising a plurality of meso-porous structures formed over the conductive current collector, and an anodically active material deposited over the three-dimensional copper-tin-iron porous conductive matrix is provided. In certain embodiments, the three-dimensional copper-tin-iron porous conductive matrix further comprises a plurality of columnar projections formed on the conductive current collector with the plurality of meso-porous structure formed on the plurality of columnar projections.

First claim

What is claimed is:

1. A method of forming a porous three-dimensional electrode microstructure, comprising:
depositing tin particles on one or more surfaces of a conductive collector substrate;
forming a three-dimensional copper-tin-iron porous conductive matrix on the tin particles and the one or more surfaces of the conductive collector substrate using an electroplating process, comprising:
positioning the conductive collector substrate in an electroplating solution;
depositing a columnar metal layer over the conductive collector substrate at a first current density by a diffusion limited deposition process; and
depositing porous conductive dendritic structures over the columnar metal layer at a second current density greater than the first current density; and

depositing an anodically active material over the three-dimensional copper-tin-iron porous conductive matrix, wherein the electroplating solution comprises a tin source, a copper source, and an iron source.

2. The method of claim 1 , further comprising:
compressing the anodically active material into the porous three-dimensional copper-tin-iron porous conductive matrix.

3. The method of claim 2 , wherein the compressing the anodically active material reduces the porosity of the electrode microstructure from an initial porosity of from about 40% to about 50% to a final porosity of from about 20% to about 30%.

4. The method of claim 2 wherein the compressing the anodically active material further comprises heating the three-dimensional copper-tin-iron porous conductive matrix and anodically active material to a temperature from about 100° C. to about 250° C.

5. The method of claim 1 , wherein the first current density is between about 0.05 A/cm 2 to about 3.0 A/cm 2 and the second current density is between about 0.3 A/cm 2 to about 3 A/cm 2 .

6. The method of claim 1 , wherein the anodically active material is deposited using at least one of chemical vapor deposition (CVD) techniques, hydraulic spray techniques, atomizing spray techniques, electrostatic spray techniques, plasma spray techniques, and thermal or flame spray techniques.

7. The method of claim 1 , wherein the anodically active material comprises particles selected from the group comprising graphite, graphene hard carbon, carbon black, carbon coated silicon, silicon carbide, amorphous silicon, crystalline silicon, silicon alloys, p-doped silicon, composites thereof and combinations thereof.

8. The method of claim 1 , wherein the electroplating solution comprises copper sulfate (CuSO 4 ), stannous sulfate, and iron chloride.

9. The method of claim 1 , wherein the electrode microstructure has a porosity of between about 20% to about 30% compared to a solid film formed from the same material.

10. The method of claim 1 , wherein the columnar metal layer has a plurality of columnar projections comprising a macro-porous structure that has a plurality of macroscopic pores between about 5 and about 200 microns in size and the porous conductive dendritic structures have a plurality of meso-pores that are between about 10 nanometers and about 1,000 nanometers in size.

11. The method of claim 1 , wherein the anodically active material comprises at least one of: silicon and graphite.

12. The method of claim 1 , wherein the three-dimensional copper-tin-iron porous conductive matrix further comprises lithium.

13. The method of claim 1 , wherein the conductive substrate is a flexible conductive substrate comprising copper.

Assignees

• Applied Materials Inc

Inventors

• Lopatin Sergey D
• Brevnov Dmitri A
• Liu Eric H
• Bachrach Robert Z
• Wang Connie P

Classifications

• H01M4/625

  Carbon or graphite · CPC title

• H01M4/1395

  of electrodes based on metals, Si or alloys · CPC title

• H01M4/0452

  from solutions · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M4/134

  Electrodes based on metals, Si or alloys · CPC title