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III.C.3 High Capacity Alloy Anodes Tabacchi – NETL, Lopatin – Applied Materials electrolyte. The porous 3DCu can accommodate the volumetric expansion during electrochemical cycling and contributes to long cycle life. The improved electrodes are assembled into prismatic battery cells and tested to demonstrate the feasibility of producing Li-ion batteries with the target energy density. Approach Experimental development focused on initial electro-deposition module which allows for 3D-porous structure formation. Baseline processes have been developed for (a) 3DCu current collector and (b) for graphite coating using a water soluble process. Extending the baseline electrode concept to the high loading 3DCuSnFe/graphite alloy electrodes should allow a) low resistivity at the electrode/current collector interface, b) fast charge transfer at the electrode/ electrolyte interface, and c) alloy expansion and contraction mitigated by reduced alloy grain size with Fe addition. Modular technological steps were developed for forming 3-3.5 mAh/cm2 cells (Figure III - 84). Figure III - 85: Single layer pouch cells (SLP) made with 3D structure electrode. Eighteen cells have been shipped to INL for testing For the pre-tested cell, the capacity retention was 81.8% at 1310 cycles. Projection from these data is that the baseline cell is capable of over 1400 cycles at 80% capacity retention at C/3 rate (Figure III - 86). Figure III - 84: Schematic diagram of process flows for manufacturing baseline cells, interim cells and final cells with 3D current collector and alloy anodes Results 3D Cu Current Collector Material. Baseline processes have been developed for (a) 3DCu current collector and (b) for graphite coating using a water soluble process. Scanning Electron Microscopy (SEM) images of 3DCu/graphite structures showed crack-free coating. 3DCu/graphite baseline cell material was studied before and after calendaring. 3DCu remained unchanged with no mechanical damage as result of calendaring. Testing rate performance in half-cell assembly vs. Li demonstrated capacity retention advantages up to 25-27% at 2C and 3C-rates. Baseline Cell Testing. 30-38 mAh single layer baseline full cells using 3DCu/graphite vs. NMC (Figure III - 85), have been assembled and shipped to INL for testing according to the USABC PHEV manual. Figure III - 86: Cycling test results for baseline cell: 3DCu/Graphite vs. NMC. Projection for capacity retention over 80% is >1400 cycles 3D CuSnFe Nano-Size Grain Material. Electro- chemical deposition has been developed for forming ~50 nm grains (Figure III - 87a) of alloy anode from Cu6Sn5(Fe). Connected nano-size grains form a conductive network of porous active material on Cu foil (Figure III - 87b). Energy Storage R&D 96 FY 2013 Annual Progress Report a) ~50 nm grain size b) conductive network Figure III - 87: a) TEM and b) high resolution SEM images of the 3DCuSnFe MaterialPDF Image | Advanced Battery Development
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