US 9,040,197 B2Granted

Electrode structure and method for making the same

AssigneeSion Power Corporation

InventorsJohn D. Affinito, Gregory K. Lowe

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Abstract

Electrode structures, and more specifically, electrode structures for use in electrochemical cells, are provided. The electrode structures described herein may include one or more protective layers. In one set of embodiments, a protective layer may be formed by exposing a lithium metal surface to a plasma comprising ions of a gas to form a ceramic layer on top of the lithium metal. The ceramic layer may be highly conductive to lithium ions and may protect the underlying lithium metal surface from reaction with components in the electrolyte. In some cases, the ions may be nitrogen ions and a lithium nitride layer may be formed on the lithium metal surface. In other embodiments, the protective layer may be formed by converting lithium to lithium nitride at high pressures. Other methods for forming protective layers are also provided.

Claims27

Dependent claims

An article for use in an electrochemical cell, comprising:

a composite structure having a first side and a second, opposing side, the composite structure comprising:
at the first side, a predominantly lithium metal electroactive portion;
at the second side, a predominantly lithium nitride portion, wherein
at a location at least 10 microns from the first side toward the second side, the composite structure is free of Li3N or has a molar ratio of Li metal to Li3N of greater than 5:1, and
at a location at least 1 micron from the second side toward the first side, the composite structure has a molar ratio of Li metal to Li3N of less than 1:1000 and a lithium ion conductivity of at least 1×10−4 S/cm, and
a gradient region comprising both lithium metal and Li3N between the first side and the second side, the gradient region having a thickness of at least 0.005 microns;
an electrolyte layer adjacent the lithium nitride portion, wherein the electrolyte layer has a yield strength of greater than 50 N/cm2, and
wherein the article is under an applied anisotropic force, the anisotropic force having a component normal to a surface of the article, wherein the component defines a pressure of at least 80 N/cm2.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 13/850,437Filed 26 Mar 2013 · continuation
Priority: 13 Oct 2011
Published: US 2013/0095380 A122 Aug 2013
Granted: 26 May 2015
Term ends: Not estimatedThe source records don’t support an estimate.

Classification17 codes

H01M 4/382
Alkaline or alkaline earth metals elements: lithium
C23C 14/00
Coating by vacuum evaporation, by sputtering or by ion implantation of the
C23C 14/0641
Characterised by the coating material: nitrides
H01M 4/0426
Physical vapour deposition: sputtering

Family

Application61/546,685Us provisional application · filed 13 Oct 2011
Application13/644,933Parent of this continuation · filed 4 Oct 2012
US 2013/0216915 A1Pre-grant publication · published 22 Aug 2013
US 2013/0095380 A1Published application
US 8,936,870 B2Related patent
US 9,040,197 B2This patent

From the US filing history. Foreign family members aren’t listed.

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