PRE-LITHIATION AND LITHIUM METAL-FREE ANODE COATINGS
A method and system for forming lithium anode devices are provided. In one embodiment, the methods and systems form pre-lithiated Group-IV alloy-type nanoparticles (NP's), for example, Li—Z where Z is Ge, Si, or Sn. In another embodiment, the methods and systems synthesize Group-IV nanoparticles and alloy the Group-IV nanoparticles with lithium. The Group-IV nanoparticles can be made on demand and premixed with anode materials or coated on anode materials. In yet another embodiment, the methods and systems form lithium metal-free silver carbon (“Ag—C”) nanocomposites (NC's). In yet another embodiment, a method utilizing silver (PVD) and carbon (PECVD) co-deposition to make anode coatings that can regulate lithium nucleation energy to minimize dendrite formation is provided.
1 . A method of making a lithiated Group-IV nanoparticle, comprising:
introducing a layer of Group-IV nanoparticles into a heated mixing vessel;
introducing a layer comprising lithium into the heated mixing vessel;
sequentially repeating introducing the layer of Group-IV nanoparticles and the layer comprising lithium into the heated mixing vessel; and
alloying the Group-IV nanoparticles and with the lithium to form the lithiated Group-IV nanoparticles.
2 . The method of claim 1 , wherein the Group-IV nanoparticles are formed from a non-thermal plasma synthesis process.
3 . The method of claim 1 , wherein the lithiated Group-IV nanoparticles are an air-stable pre-lithiation reagent.
4 . The method of claim 1 , wherein introducing the layer of Group-IV nanoparticles into the heated mixing vessel comprises supplying molten lithium into the heated mixing vessel.
5 . The method of claim 1 , wherein introducing the layer of Group-IV nanoparticles into the heated mixing vessel comprises supplying lithium powder into the heated mixing vessel.
6 . The method of claim 1 , further comprising applying the lithiated Group-IV nanoparticles to a graphite anode to form a pre-lithiated graphite anode.
7 . The method of claim 6 , wherein applying the lithiated Group-IV nanoparticles to a graphite anode to form a pre-lithiated graphite anode comprises an industrial sifter feeder process.
8 . The method of claim 6 , wherein applying the lithiated Group-IV nanoparticles to a graphite anode to form a pre-lithiated graphite anode comprises an electrospray process.
9 . The method of claim 1 , wherein the Group-IV nanoparticles are selected from silicon nanoparticles, germanium nanoparticles, tin nanoparticles, carbon nanoparticles, or any combination thereof.
10 . The method of claim 1 , wherein the heated mixing vessel is a rotary planetary mixer.
11 . The method of claim 10 , further comprising mixing the lithiated Group-IV nanoparticles to form a slurry.
12 . The method of claim 11 , wherein mixing the lithiated Group-IV nanoparticles to form the slurry comprises mixing the lithiated Group-IV nanoparticles with a conductive additive, a binding agent, a solvent, or any combination thereof.
13 . The method of claim 12 , further comprising casting the slurry over an anode structure to form a pre-lithiated alloy-type anode.
14 . A system for forming an anode structure, comprising:
a lithium source module operable to supply lithium;
a Group-IV nanoparticle source module operable to supply Group-IV nanoparticles; and
a mixing vessel assembly, wherein the mixing vessel assembly is capable of heating the lithium and the Group-IV nanoparticles to produce pre-lithiated Group-IV alloy-type nanoparticles.
15 . The system of claim 14 , further comprising a deposition source module operable to deposit the pre-lithiated Group-IV alloy-type nanoparticles over a substrate.
16 . The system of claim 15 , wherein the deposition source module comprises:
a sifter body;
a hopper assembly; and
a delivery conduit fluidly coupling the hopper assembly with the sifter body.
17 . The system of claim 15 , wherein the deposition source module comprises:
a deposition module that defines a processing environment;
a coating drum positioned in the processing environment and operable to transfer a flexible substrate; and
an electrospray gun positioned in the processing environment and operable to deposit the pre-lithiated Group-IV alloy-type nanoparticles on the flexible substrate.
18 . The system of claim 17 , wherein the electrospray gun is a triboelectric powder spray gun or a corona spray gun.
19 . The system of claim 18 , further comprising: a hopper assembly operable for storing and supplying the lithiated Group-IV alloyed nanoparticles to the electrospray gun.
20 . A flexible substrate coating system, comprising:
an unwinding module housing a feed reel capable of providing a continuous sheet of flexible material;
a winding module housing a take-up reel capable of storing the continuous sheet of flexible material;
a processing module arranged downstream from the unwinding module, the processing module, comprising:
a plurality of sub-chambers arranged in sequence, each configured to perform one or more processing operations to the continuous sheet of flexible material; and
a coating drum capable of guiding the continuous sheet of flexible material past the plurality of sub-chambers along a travel direction, wherein the sub-chambers are radially disposed about the coating drum and a first sub-chamber of the plurality of sub-chambers, comprises:
a first deposition source operable to deposit silver; and
a second deposition source operable to deposit carbon.