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III.C.3 High Capacity Alloy Anodes (Applied Materials) John Tabacchi, NETL Project Manager Grant Recipient: Applied Materials, Inc. Sergey Lopatin, Project Director/Principal Investigator 3100 Bowers Avenue, M/S 202 Santa Clara, CA 95052 Phone: (408) 235-4742; Fax: (408) 235-6863 E-mail: sergey_lopatin@amat.com Subcontractors: Lawrence Berkeley National Laboratory Oak Ridge National Laboratory FMC Lithium Division Navitas Systems Nissan Technical Center North America Start Date: October 1, 2011 Projected End Date: September 30, 2014 Objectives Develop and demonstrate the feasibility of depositing alloy anode materials at high deposition rates. Characterize, evaluate, and optimize the resulting electrodes using pouch cells and demonstrate the low cost potential of the new manufacturing methodology. Technical Barriers Cycle life of alloy based anodes is one of the main issues that limit their viability. We are working closely with our partners (subcontractors) to understand the underlying issues leading to the low cycle life of these anodes and then make necessary process changes to meet requirements. Technical Targets Demonstrate high capacity Li-ion battery cell anodes that are capable of achieving an energy density of at least 500 Wh/l and a power density of at least 500 W/l. Demonstrate cycle life (300-1,000 cycles at 80% depth of discharge), calendar life (5-10 years), and durable cell construction and design capable of being affordably mass produced. Accomplishments Development of electro-deposition module which allows for 3D-porous structure formation in a single prototype tool for both 3D Cu collector and 3D CuSnFe alloy anode. Development of modular technological steps for forming 3-3.5 mAh/cm2 cells including process methodology for Graphite coating by water soluble process to achieve adhesion to the 3D-porous structures. Testing rate performance in half-cell assembly vs. Li demonstrated capacity retention advantages up to 25-27% at 2C and 3C-rates. Testing baseline pouch cell assembly. Porous 3D electrodes were assembled in single layer pouch cells with Li1-x[Ni1/3Mn1/3Co1/3]O2 (NMC) cathodes. The retention capacity for 3DCu/Graphite vs. NMC was measured 81.8% at 1310 cycles. Projection from these data is that the baseline cell is capable of over 1,400 cycles at capacity retention of 80% at C/3 rate. Eighteen cells comprised the program’s 1st deliverable sent to Idaho National Laboratory (INL) for further evaluation. Development of 3DCuSnFe nano-structure alloy anode. Coulombic efficiency (CE) is improved by grain size reduction, pre- lithiation, and mitigation with combining alloy with Graphite. Extending 3D electrode concept to the high loading 3DCuSnFe/Graphite alloy electrodes and testing interim pouch cell. Capacity retention of 76.2% at 1280 cycles was demonstrated. These data show that the interim cell is capable of 985 cycles at 80% capacity retention at C/3 rate. Introduction Applied Materials is working on a new class of Li battery anodes with high capacity based on an innovative micro-cell porous 3DCu-Li alloy structure. Micro-cell 3DCu-Li alloy architecture of controlled thickness forms continuous highly conductive Cu pathways for electrons through the full electrode. The technology holds great potential for electric vehicle lithium-ion batteries. The electrode structure also has a very large surface to volume ratio to contact with Li-ion FY 2013 Annual Progress Report 95 Energy Storage R&DPDF Image | Advanced Battery Development
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