Colloidal sphere templates and sphere-templated porous materials
AssigneeThe Regents of the University of California
InventorsJohn H. Harreld, Galen D. Stucky, Nathan L. Mitchell, Jeff S. Sakamoto
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Abstract
A method of making colloidal sphere templates and the sphere-templated porous materials made from the templates. The templated porous materials or thin films comprise micron and submicron-scaled spheres in ordered, disordered, or partially ordered arrays. The invention is useful in the synthesis of submicron porous, metallic tin-based and other high capacity anode materials with controlled pore structures for application in rechargeable lithium-ion batteries. The expected benefits of the resulting nanostructured metal films include a large increase in lithium storage capacity, rate capability, and improved stability with electrochemical cycling.
Claims22
A process for colloidal sphere-templated electrodeposition of a porous metal structure at least partially disordered, comprising:
- a) providing an electrode substrate;
- b) applying a dispersion onto the surface of the substrate, said dispersion being a liquid phase suspension of colloidal particles comprising of particles that are substantially spherical in shape and have a standard deviation in sphere diameter of greater than about 5%;
- c) removing the liquid phase to form a sacrificial template comprising an array of close packed colloidal spheres defining an interstitial volume;
- d) electrodepositing a metal plating solution onto the array to form a metallic replica of the array interstitial volume having a pore distribution corresponding to the spheres;
- and
- e) removing the sacrificial template to form said porous metal structure.
A process for colloidal sphere-templated electrodeposition of a porous metal structure at least partially disordered for use in an electrode, comprising:
- a) providing an electrode substrate;
- b) applying a thin layer of tin onto the electrode substrate;
- c) applying a dispersion onto the surface of the substrate, said dispersion being a liquid phase suspension of colloidal particles substantially spherical in shape and have a standard deviation in sphere diameter of greater than about 5%;
- d) removing the liquid phase to form a sacrificial template comprising an array of close packed colloidal spheres defining an interstitial volume, wherein the colloidal spheres are polystyrene, polymethylmethacrylate, surface-functionalized polymer, or silica;
- e) electrodepositing a metal plating solution onto the array to form a metallic replica of the array interstitial volume having a pore distribution corresponding to the spheres;
- and
- f) removing the sacrificial template to form said porous metal structure.
A process for colloidal sphere-templated electrodeposition of a porous tin or tin alloy structure at least partially disordered, comprising:
- a) providing an electrode substrate;
- b) applying a dispersion onto the surface of the substrate, said dispersion being a liquid phase suspension of colloidal particles comprising of particles that are substantially spherical in shape and have a standard deviation in sphere diameter of greater than about 5%;
- c) removing the liquid phase to form a sacrificial template comprising an array of close packed colloidal spheres defining an interstitial volume, wherein the colloidal spheres are polstyrene, polylmethylmethacrylate, surface-functionalized polymer, or silica;
- d) electrodepositing a metal plating solution onto the array to form a metallic replica of the array interstitial volume having a pore distribution corresponding to the spheres;
- and
- e) removing the sacrificial template to form said porous metal structure.
A process for the formation of a template, comprising:
- a) providing an electrode substrate;
- b) applying a dispersion onto the surface of the substrate, said dispersion being a liquid phase suspension of colloidal particles comprising of particles that are substantially spherical in shape and have a standard deviation in sphere diameter of greater than about 5%;
- and
- c) removing the liquid phase to form a sacrificial template comprising an array of close packed colloidal spheres defining an interstitial volume.
A porous metal or metal oxide film having pores of mean diameter within the range of about 10 nm to about 1000 nm, with a deviation from the mean of no more than about 5%, wherein said pores are connected to each other.
A porous metal film having pores of mean diameter within the range of about 10 nm to about 1000 nm, with a deviation from the mean of more than about 5%, wherein said pores are connected to each other.
A porous electrode film having pores of mean diameter within the range of about 10 nm to about 1000 nm, with a deviation from the mean of more than about 5%, wherein said pores are connected to each other.
A porous Sn film having pores of mean diameter within the range of about 10 nm to about 1000 nm, with a deviation from the mean of more than about 5%, wherein said pores are connected to each other.
Dependencies are inferred from the claim text.