Thermally protective salt material for thermal spraying of electrode materials
First Claim
1. A method for the manufacture of an electrode for an energy storage and conversion device, comprisingthermally spraying a feedstock mixture comprising an effective quantity of a source of a thermally protective salt and an active material or active material precursor onto a substrate to produce a film of the active material and salt wherein the film has a thickness of about 1 to about 1000 microns wherein the source of the thermally protective salt is a LiCl—
- KCl eutectic, LiBr—
KBr—
LiF, LiCl—
LiBr—
LiF, a carbonate-based system with a melting point below about 500°
C., or a sulfate-based system with a melting point below about 500°
C.
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Abstract
A method for the manufacture of an electrode for an energy storage or conversion device comprises thermally spraying a feedstock mixture comprising an effective quantity of a source of a thermally protective salt and an active material or active material precursor onto a substrate to produce a film of the active material and salt. The film can have a thickness of about 1 to about 1000 microns.
In a particularly advantageous feature, the active materials which ordinarily decompose or are unavailable at the high temperatures used during thermal spray processes, such as metal chalcogenides such as pyrite, CoS2, WS2, Ni(OH)2, MnO2, and the like may be thermally sprayed to form an electrode when the feedstock mixture employs an effective amount of a source of the thermally protective salt coating. The active material feedstock may comprise microstructured or nanostructured materials, which after thermal spray results in electrodes having microstructured or nanostructured active materials, respectively.
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Citations
37 Claims
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1. A method for the manufacture of an electrode for an energy storage and conversion device, comprising
thermally spraying a feedstock mixture comprising an effective quantity of a source of a thermally protective salt and an active material or active material precursor onto a substrate to produce a film of the active material and salt wherein the film has a thickness of about 1 to about 1000 microns wherein the source of the thermally protective salt is a LiCl— - KCl eutectic, LiBr—
KBr—
LiF, LiCl—
LiBr—
LiF, a carbonate-based system with a melting point below about 500°
C., or a sulfate-based system with a melting point below about 500°
C. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
- KCl eutectic, LiBr—
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14. A method for the manufacture of an electrode for an energy storage and conversion device, comprising
ball-milling an active material comprising a metal chalcenogide or metal chalcenogide precursor with about 10% to about 30% by weight based on the total weight of the composition of a source of a thermally protective salt, to provide a feedstock for thermal spray; - and
thermally spraying the feedstock for thermal spray onto a substrate, to produce an active material film wherein the source of the thermally protective salt is a LiCl—
KCl eutectic, LiBr—
KBr—
LiF, LiCl—
LiBr—
LiF, a carbonate-based system with a melting point below about 500°
C., or a sulfate-based system with a melting point below about 500°
C.- View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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26. A electrode for an energy storage and conversion device, comprising
a substrate; - and
a layer of active material comprising a thermally protective salt deposited on the substrate, the layer having a thickness of about 1 to about 200 microns wherein the active material is unsuitable without the thermally protective salt for use in an electrode at thermal spray temperatures further wherein the thermally protective salt is derived from a source of a thermally protective salt which a LiCl—
KCl eutectic, LiBr—
KBr—
LiF, LiCl—
LiBr—
LiF, a carbonate-based system with a melting point below about 500°
C., or a sulfate-based system with a melting point below about 500°
C.- View Dependent Claims (27, 28, 29, 30)
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31. A method for the manufacture of an electrode, comprising
providing a feedstock comprising pyrite and an effective quantity of a source of a thermally protective salt; - and
thermally spraying the feedstock onto a substrate, to produce a film of salt coated pyrite active material having a thickness of about 1 to about 1000 microns wherein the source of the thermally protective salt is a LiCl—
KCl eutectic, LiBr—
KBr—
LiF, LiCl—
LiBr—
LiF, a carbonate-based system with a melting point below about 500°
C., or a sulfate-based system with a melting point below about 500°
C.- View Dependent Claims (32, 33, 34)
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35. A method for the manufacture of a cathode, comprising
ball-milling pyrite with about 10% to about 30% by weight based on the total weight of the composition of a source of a thermally protective salt to provide a feedstock comprising a source of a thermally protective salt coating and pyrite; - and
thermally spraying the feedstock solution onto a substrate to produce a film of salt coated pyrite active material having a thickness of about 1 to about 200 microns wherein the source of the thermally protective salt is a LiCl—
KCl eutectic, LiBr—
KBr—
LiF, LiCl—
LiBr—
LiF, a carbonate-based system with a melting point below about 500°
C., or a sulfate-based system with a melting point below about 500°
C.- View Dependent Claims (36, 37)
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Specification