Li-ion battery and battery active components on metal wire

• US 8,993,172 B2
• Filed: 12/07/2012
• Issued: 03/31/2015
• Est. Priority Date: 12/10/2011
• Status: Active Grant

• Current Assignee: Kalptree Energy, Inc.
• Original Assignee: Kalptree Energy, Inc.
• Inventors: Upadhyaya, Deepak
• Primary Examiner(s): Walls, Cynthia K.
• Application Number:
  US13/708,137
• Publication Number:
  US 20130344363A1
• Time in Patent Office: 844 Days
• Field of Search: None
• US Class Current: 429/238
• CPC Class Codes: H01M 10/0422 Cells or battery with cylindrical casing
• CPC Class Codes: H01M 10/049 Processes for forming or storing electrodes in the battery container
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 10/0587 of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2004/022 Electrodes made of one single microscopic fiber
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0428 Chemical vapour deposition
• CPC Class Codes: H01M 4/0471 involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
• CPC Class Codes: H01M 4/133 Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/1393 of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/1395 of electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/386 Silicon or alloys based on silicon
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/75 Wires, rods or strips
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

A battery on a conductive metal wire and components of a battery on a conductive metal wire of circular cross section diameter of 5-500 micrometers and methods of making the battery and battery components are disclosed. In one embodiment, the battery features a porous anode or cathode layer which assist with ion exchange in batteries. Methods of forming the porous anode or cathode layer include deposition of an inert gas or hydrogen enriched carbon or silicon layer on a heated metal wire followed by annealing of the inert gas or hydrogen enriched carbon silicon layer. Energy storage devices having bundles of batteries on wires are also disclosed as are other energy storage devices.

Claims

1. A battery comprising:

a conductive metal wire with a diameter in the range of 5-500 micrometers having a circular cross section;

a first layer disposed on the metal wire;

a second layer formed on the first layer, wherein one of the first and second layers is carbon and the other is silicon, the metal wire and the first and second layers forming a first electrode;

a cylindrical second electrode spaced apart from the first electrode; and

an electrolyte occupying the space between the first and second electrodes;

wherein the first and second layers have pores formed therein and the pores provide an enlarged area for ion exchange between the first and second electrodes.

2. The battery of claim 1 wherein when the carbon layer is the first layer and the silicon layer is the second layer, further including a second carbon layer disposed on the silicon layer.

3. The battery of claim 2 further comprising another silicon layer disposed on the second carbon layer.

4. A battery comprising:

a conductive metal wire with a diameter in the range of 5-500 micrometers having a circular cross section;

a first layer disposed on the metal wire;

a second layer formed on the first layer, wherein one of the first and second layers is carbon and the other is silicon, the metal wire and the first and second layers forming a first electrode;

a cylindrical second electrode spaced apart from the first electrode; and

an electrolyte occupying the space between the first and second electrodes;

wherein the first layer is an inert gas or hydrogen enriched silicon or carbon layer.

5. A battery, comprising:

a first electrode including an anode wire having a circular cross section and surrounded by a separator;

a removable mandrel tube including a surface defining a hollow chamber, the first electrode wire wrapped around the removable mandrel tube;

a second electrode including a cathode wire having a circular cross section, the second electrode wrapped around the first electrode;

a casing material encasing the first and second electrodes and the removable mandrel tube; and

an electrolyte disposed in the hollow chamber.