Single-Target Sputtering for Nanostructured Li-Ion Battery Electrodes
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Solution Overview
Problem
Lithium metal anodes in rechargeable batteries face safety concerns due to reactivity, limiting their use, and existing cathode materials like lithium cobalt oxide (LiCoO2) require separate production processes for cathodes and anodes, hindering manufacturing efficiency.
Innovation Solution
A nanostructured battery process using sputter deposition from a single lithium cobalt oxide (LiCoO2) target source to produce both cathode and anode materials, including a metal oxide anode (Co3O4) and lithiated metal oxide cathode (LiCoO2), in a high-pressure, oxygen-saturated environment, enhancing surface area and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lithium metal is used as anode material to achieve high specific capacity, then capacity is improved, but safety deteriorates due to extreme reactivity
Solution Approach 1:
The patent changes the chemical composition parameter of the anode material from pure lithium metal to lithium cobalt oxide, transforming the material properties to achieve both high capacity and improved safety through controlled reactivity
Solution Approach 2:
The patent uses lithium cobalt oxide as a composite material that combines lithium with cobalt oxide, creating a new material class that maintains high lithium ion capacity while reducing the extreme reactivity hazards of pure lithium metal
2Manufacturing precision
If separate production processes are used for cathode and anode materials, then material quality is maintained, but manufacturing efficiency deteriorates
Solution Approach 1:
The patent merges the separate production processes for cathode and anode materials into a single sputtering process that deposits both electrode materials simultaneously from one target, dramatically improving manufacturing efficiency while maintaining material quality through controlled deposition parameters
Solution Approach 2:
The patent makes the sputtering target universal by using lithium cobalt oxide that can serve as both cathode material and anode material source, allowing one target to produce both electrodes and eliminating the need for separate production lines
3Ease of manufacture
If conventional sputtering is used for deposition, then manufacturing process is simple, but surface area and performance are limited
Solution Approach 1:
The patent changes the sputtering process parameters including using low power deposition, high pressure environment, and oxygen saturation to transform the deposition outcome from conventional thin films to nanostructured materials with dramatically increased surface area and enhanced electrochemical performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves high capacity and energy density with improved cyclability, rivaling commercial standards by producing electrodes with enhanced performance and efficiency, allowing for large-scale battery production with increased throughput.
Implementation Method 1
The process includes the steps of deposition sputtering on a substrate from a metal oxide target source to produce an anode
Implementation Method 2
The steps of deposition sputtering to produce a cathode and deposition sputtering to produce an anode are performed at low power in a high pressure, oxygen saturated environment
Data Source
AI summary
A process of sputter deposition of both a cathode material and an anode material from a single target source. The process includes the steps of deposition sputtering on a porous substrate from a lithiated metal oxide target source to produce an anode. In addition, deposition sputtering on a porous substrate from the same lithiated metal oxide target source is utilized to produce a cathode. A nanostructured battery may be produced having a metal oxide anode and a lithiated metal oxide cathode, wherein the anode and the cathode are generated from a single target source.