IP Library › Granted Patent US 12,431,480
Granted Patent B2
US 12,431,480 · App. 18/824,719 · Granted Sep 30, 2025

Methods for forming an energy storage device

Inventor: Emilie Bodoin (Charlestown, MA)
Assignee: PURE LITHIUM CORPORATION
H01M4/0452C25D1/04C25D1/20C25D5/611H01M4/134H01M4/1395C25D5/10C25D5/12H01M2004/021H01M2004/027
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Quick Facts
Patent No.
US 12,431,480
App. No.
18/824,719
Granted
Sep 30, 2025
Kind
B2
Abstract

Methods are proposed for manufacturing dendrite-resistant lithium metal electrodes suitable for incorporation into lithium metal batteries. In an embodiment, the method involves first electroplating a copper sheet onto a surface of a single crystal of silicon, the silicon being doped to form a p-type or an n-type semiconductor, and then further electroplating the copper sheet with lithium metal. The lithium-electroplated copper sheet thus manufactured provides a lithium electrode that is resistant to dendrite formation during cycling of lithium metal batteries when compared to conventionally manufactured lithium electrodes. Methods are further provided of manufacturing lithium sheets by directly electroplating lithium metal onto single crystals of doped silicon, the lithium sheets configured for incorporation into lithium metal electrodes that are resistant to dendrite formation during cycling of lithium metal batteries.

Claims (32)

1. A method for forming an energy storage device, comprising:

(a) providing a device comprising a (i) conductive substrate and (ii) a lithium-ion selective membrane adjacent to the conductive substrate, wherein the lithium-ion selective membrane comprises a polymeric matrix and a plurality of ion-conducting particles disposed within the polymeric matrix; and

(b) in an inert atmosphere, applying a current to the device, thereby flowing a plurality of lithium ions through the lithium-ion selective membrane towards the conductive substrate to form a layer of lithium metal coupled to the conductive substrate, thereby forming a negative electrode of the energy storage device, wherein the lithium-ion selective membrane allows passage of the plurality of lithium ions while substantially precluding passage of one or more non-metallic elements to the conductive substrate, and wherein the layer of lithium metal has (i) a density of at least 0.4 g/cm 3 , (ii) a thickness between 1 micrometer and 50 micrometers, and (iii) a content of less than 300 parts-per-million (ppm) by mass of the one or more non-metallic elements,

wherein the energy storage device comprises a positive electrode and the negative electrode, wherein the negative electrode comprises the layer of the lithium metal coupled to the conductive substrate, and wherein the lithium-ion selective membrane is disposed between the negative electrode and the positive electrode.

2. The method of claim 1 , wherein the negative electrode has a specific capacity of at least about 3800 milliampere-hours per gram (mAh/g).

3. The method of claim 1 , wherein the energy storage device is a rechargeable energy storage device.

4. The method of claim 1 , further comprising using the energy storage device to provide electrical energy to a load operably coupled to the energy storage device.

5. The method of claim 1 , wherein the current is from about 10 mA/cm 2 to about 50 mA/cm 2 .

6. The method of claim 1 , wherein the current is applied for a time duration between about 1 minute and about 60 minutes.

7. The method of claim 1 , wherein the layer of lithium metal is electrodeposited on the conductive substrate using an aqueous lithium salt solution in proximity to the lithium-ion selective membrane.

8. The method of claim 7 , wherein the aqueous lithium salt solution provides a source of the plurality of lithium ions.

9. The method of claim 7 , wherein the aqueous lithium salt solution comprises LiCI, Li 2 SO 4 or Li 2 CO 3 , or a combination thereof.

10. The method of claim 7 , wherein the aqueous lithium salt solution is brine.

11. The method of claim 1 , wherein the layer of lithium metal comprises (i) a first surface adjacent to the conductive substrate and (ii) a second surface adjacent to the lithium-ion selective membrane.

12. The method of claim 1 , wherein the density of the layer of lithium metal is from about 0.45 g/cm 3 to about 0.543 g/cm 3 .

13. The method of claim 1 , wherein the conductive substrate comprises copper, aluminum, graphite coated copper, or nickel.

14. The method of claim 1 , wherein the polymeric matrix comprises a silica-based polyurethane, polyethylene oxide, polystyrene, or polyamide.

15. The method of claim 1 , wherein the polymeric matrix comprises an inorganic coating.

16. The method of claim 1 , wherein the plurality of ion-conducting particles comprises a plurality of ceramic particles.

17. The method of claim 1 , wherein the plurality of ion-conducting particles comprises LiFePO 4 , LiCoO 2 , NASICON electrolytes, lithium-lanthanum titanates (LLTO), garnet type electrolytes, LISICON and Thio-LISICON electrolytes, LizLa 3 Zr 3 O 12 (LLZO), or cubic phase c-LLZO.

18. The method of claim 1 , wherein the layer of lithium metal is substantially free of the one or more non-metallic elements.

19. The method of claim 1 , wherein the layer of lithium metal has a content of less than 5 ppm by mass of the one or more non-metallic elements.

20. The method of claim 1 , wherein the one or more non-metallic elements comprises nitrogen, and wherein the layer of lithium metal has a content of less than 5 ppm of nitrogen.

21. The method of claim 1 , wherein the layer of lithium metal is substantially free of Li 3 N.

22. The method of claim 1 , wherein the lithium-ion selective membrane substantially precludes passage of water to the conductive substrate.

23. The method of claim 1 , wherein the inert atmosphere is inert to chemical reaction with lithium.

24. The method of claim 1 , wherein the inert atmosphere includes no more than 10 ppm of lithium reactive components on a molar basis.

25. The method of claim 1 , wherein the inert atmosphere includes no more than 5 ppm of lithium reactive components on a molar basis.

26. The method of claim 1 , wherein the inert atmosphere includes no more than 10 ppm of nitrogen on a molar basis.

27. The method of claim 1 , wherein the inert atmosphere includes no more than 5 ppm of nitrogen on a molar basis.

28. The method of claim 1 , wherein the energy storage device is a battery.

29. The method of claim 28 , wherein the negative electrode operates as an anode during discharge of the battery.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 27, 2025
From: BODOIN, EMILIE
To: PURE LITHIUM CORPORATION
Reel/Frame 072591/0769 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 20, 2025
From: SADOWAY, DONALD R.
To: PURE LITHIUM CORPORATION
Reel/Frame 070281/0604 →
Continuity (7)
Continuation In Part 17581517 · Jan 21, 2022
Continuation In Part 18236257 · Aug 21, 2023
Continuation In Part 18101261 · Jan 25, 2023
Continuation 17006048 · Aug 28, 2020
Continuation In Part 17006073 · Aug 28, 2020
Provisional Application 63143178 · Jan 29, 2021
Related Publication 20250006886A1 · Jan 2, 2025
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