POROUS CURRENT COLLECTOR AND ELECTRODE FOR AN ELECTROCHEMICAL BATTERY

Abstract

A component for use in an electrochemical battery, wherein the component includes a self-supporting porous metal substrate capable of acting as both an electrode and a current collector in an electrochemical battery. The present disclosure is also directed to methods of making the components of the present disclosure and electrochemical batteries including at least one component according to the present disclosure.

Claims

1. A component for use in an electrochemical battery, wherein the component includes a self-supporting porous metal substrate, wherein the self-supporting porous metal substrate is electrically conductive, and wherein the self-supporting porous metal substrate comprises a plurality of pores capable of ion insertion and extraction.

2. The component of claim 1, wherein the self-supporting porous metal substrate comprises copper.

3. The component of claim 1, wherein the component has a specific capacity in an electrochemical battery that is greater or less than about 350 Ah/kg.

4. The component of claim 1, wherein the plurality of pores have an average diameter of from about 0.1 to 40 nm.

5. The component of claim 4, wherein the plurality of pores have an average diameter of from about 1 to 10 nm.

6. The component of claim 1 further comprising a carbon-containing material.

7. The component of claim 6, wherein the carbon-containing material is a coating provided on a surface of the porous metal substrate.

8. The component of claim 7, wherein the carbon-contains material is graphene.

9. The component of claim 1, wherein the self-supporting porous metal substrate has a pore size distribution that is the same as that of a hard carbon material.

10. The component of claim 9, wherein an exterior surface of the self-supporting porous metal substrate and at least a portion of an interior surface of the self-supporting porous metal substrate defining the plurality of pores is coated with a carbon-containing material.

11. The component of claim 10, wherein the carbon-containing material is graphene, and wherein the graphene is applied to the self-supporting porous metal substrate by chemical vapor deposition.

12. The component of claim 1, wherein the self-supporting porous metal substrate is prepared by sintering a plurality of copper nanoparticles and/or a copper metal precursor to form the self-supporting porous metal substrate.

13. The component of claim 1, wherein the self-supporting porous metal substrate is prepared by providing a copper-containing alloy and chemically or electrochemically dealloying the copper-containing alloy to form the self-supporting porous metal substrate.

14. The component of claim 1, wherein the self-supporting porous metal substrate comprises a porous copper first layer positioned on a non-porous copper second layer.

15. An electrochemical battery comprising: an electrolyte; a cathode; a current collector in communication with an external face of the cathode; a component comprising a self-supporting porous metal substrate; and a separator positioned between the cathode and the component, wherein the self-supporting porous metal substrate is electrically conductive and comprises a plurality of pores capable of ion insertion and extraction, and wherein the component acts as an anode and a current collector in the lithium ion battery.

16. The electrochemical battery of claim 15, wherein the self-supporting porous metal substrate comprises copper.

17. The electrochemical battery of claim 15, wherein the component has a specific capacity in an electrochemical battery that is greater or less than about 350 Ah/kg.

18. The electrochemical battery of claim 15, wherein the plurality of pores have an average diameter of from about 0.1 to 40 nm.

19. The electrochemical battery of claim 18, wherein the plurality of pores have an average diameter of from about 1 to 10 nm.

20. The electrochemical battery of claim 15 further comprising a carbon-containing material provided on a surface of the porous metal substrate.

21. The electrochemical battery of claim 20, wherein the carbon-containing material is graphene.

22. The electrochemical battery of claim 15, wherein the self-supporting porous metal substrate has a pore size distribution that is the same as that of a hard carbon material.

23. The electrochemical battery of claim 15, wherein an exterior surface of the self-supporting porous metal substrate and at least a portion of an interior surface of the self-supporting porous metal substrate defining the plurality of pores is coated with a carbon-containing material.

24. The electrochemical battery of claim 23, wherein the carbon-containing material is graphene, and wherein the graphene is applied to the self-supporting porous metal substrate by chemical vapor deposition.

25. The electrochemical battery of claim 15, wherein the self-supporting porous metal substrate is prepared by sintering a plurality of copper nanoparticles and/or a copper metal precursor to form the self-supporting porous metal substrate.

26. The electrochemical battery of claim 15, wherein the self-supporting porous metal substrate is prepared by providing a copper-containing alloy and chemically or electrochemically dealloying the copper-containing alloy to form the self-supporting porous metal substrate.

27. The electrochemical battery of claim 15, wherein the self-supporting porous metal substrate comprises a porous copper first layer positioned on a non-porous copper second layer.

28. A method of making a lithium-ion battery comprising: providing a self-supporting copper substrate that is electrically conductive and comprises a plurality of pores capable of ion insertion and extraction; assembling an electrochemical battery comprising a cathode, a combined anode and current collector comprising the self-supporting copper substrate, and a separator positioned between the cathode and anode.

29. The method of claim 28, wherein the self-supporting copper substrate has a pore size distribution that is the same as that of a hard carbon material.

30. The method of claim 29, wherein an exterior surface of the self-supporting copper substrate and at least a portion of an interior surface of the self-supporting copper substrate defining the plurality of pores is coated with a carbon-containing material.

31. The method of claim 30, wherein the carbon-containing material is graphene and the step of providing the self-supporting copper substrate includes applying the graphene to the self-supporting copper substrate by chemical vapor deposition.

32. The method of claim 28, wherein the step of providing the self-supporting copper substrate comprises sintering a plurality of copper nanoparticles and/or a copper metal precursor to form the self-supporting copper substrate.

33. The method of claim 28, wherein the step of providing the self-supporting copper substrate includes providing a copper-containing alloy and chemically or electrochemically dealloying the copper-containing alloy to form the self-supporting copper substrate.

34. The method of claim 28, wherein the self-supporting copper substrate comprises a porous copper first layer positioned on a non-porous copper second layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a schematic depicting an example of sintering a plurality of nanoparticles, according to aspects of the present disclosure.

[0011] FIG. 2a shows an example of an LIB, according to aspects of the present disclosure.

[0012] FIG. 2b shows an example of an LIB, according to aspects of the present disclosure.

[0013] FIG. 3 shows a coin cell battery construction including a reference electrode including a separate current collector.

[0014] FIGS. 4a, 4b, 4c, and 4d show the performance of the reference electrode of FIG. 3 after each of three cycles of charging and discharging.

[0015] FIG. 5 shows a coin cell battery construction including a microporous copper electrode without a separate current collector according to the present disclosure.

[0016] FIG. 6a shows scanning electron microscope images of the surface of the microporous copper electrode of the coin cell battery construction of FIG. 5 according to the present disclosure before three cycles of charging and discharging.

[0017] FIG. 6b shows scanning electron microscope images of the surface of the microporous copper electrode of the coin cell battery construction of FIG. 5 according to the present disclosure after three cycles of charging and discharging.

[0018] FIGS. 7a, 7b, 7c, and 7d shows the performance of the microporous copper electrode of the coin cell battery construction of FIG. 5 according to the present disclosure after each of three cycles of charging and discharging.

[0019] FIG. 8 shows a coin cell battery construction including a nanoporous copper electrode without a separate current collector according to the present disclosure.

[0020] FIG. 9a shows scanning electron microscope images of the surface of the nanoporous copper electrode of the coin cell battery construction of FIG. 8 according to the present disclosure before three cycles of charging and discharging.

[0021] FIG. 9b shows scanning electron microscope images of the surface of the nanoporous copper electrode of the coin cell battery construction of FIG. 8 according to the present disclosure after three cycles of charging and discharging.

[0022] FIG. 10a shows the capacity of the nanoporous copper electrode of the coin cell battery construction of FIG. 8 according to the present disclosure after each of three cycles of charging and discharging.

[0023] FIG. 10b shows electromotive force vs. capacity of the nanoporous copper electrode of the coin cell battery construction of FIG. 8 according to the present disclosure for each of three cycles of charging and discharging.

[0024] FIGS. 10c and 10d show additional performance characteristics of the nanoporous copper electrode of the coin cell battery construction of FIG. 8 according to the present disclosure after each of three cycles of charging and discharging.

[0025] FIGS. 11a, 11b, 11c, and 11d show the results of Brunauer-Emmett-Teller (BET) surface area measurements corresponding to an example hard carbon material according to the present disclosure.

[0026] FIGS. 12a and 12b show mercury porosity measurements corresponding to an example hard carbon material according to the present disclosure.

[0027] Table 1 illustrates how the capacity was estimated for the coin cell battery construction including the nanoporous copper electrode shown in FIG. 8.

[0028] Table 2 illustrates how the capacity was estimated for the coin cell battery construction including the microporous copper electrode shown in FIG. 5.

[0029] Table 3 illustrates how the capacity was estimated for the coin cell battery construction including a reference electrode as shown in FIG. 3.

DETAILED DESCRIPTION

[0030] The present disclosure is generally directed to a component for use in an electrochemical battery, wherein the component includes a self-supporting porous metal substrate capable of acting as both an electrode and a current collector in an electrochemical battery. Optionally, the pores of the metal substrate may be tailored to have the same diameter or other dimensions of a hard carbon material. While the present disclosure will be described in terms of an LIB, it should be understood that any electrochemical battery capable of performing according to the present disclosure may be used. Example electrochemical batteries that may be used according to certain aspects of the present disclosure include lithium-sulphur, sodium ion, and lead acid, among others.

[0031] According to some aspects, the porous metal substrate may be electrically conductive. According to some aspects, the porous metal substrate may comprise a plurality of pores with a particular pore size and/or distribution capable of ion intercalation and release. The present disclosure is also directed to methods of making the components of the present disclosure.

[0032] According to some aspects of the present disclosure, the component may comprise a porous metal substrate capable of reacting interstitially with ions, for example, lithium ions, thereby acting as an electrode (e.g., an anode) in an electrochemical battery, for example, an LIB. For example, in the case of an LIB, the component may comprise a porous metal substrate with pores capable of taking up and releasing lithium ions (i.e., lithium ion insertion and extraction) through intercalation or a similar process. As used herein, the term “pore” refers to an opening or depression in the surface, or a tunnel, in the porous metal substrate. According to some aspects, the porous metal substrate may comprise a pore size, pore volume, surface area, density, pore size distribution, and/or pore length similar to a hard carbon material that provides a high capacity electrode in an electrochemical battery, while reducing the risk for the formation of dendrites.

[0033] According to some aspects, the pores may have a pore size of from about a few nanometers up to hundreds of micrometers. For example, the pores may have a pore diameter in the range of about 0.001 to 300 nm, preferably in the range of about 0.01 to 200 nm, and more preferably in the range of about 0.1 to 150 nm. According to some aspects, the pores may have an average pore diameter of from about 0.1 to 20 nm, preferably from about 0.1 to 15 nm, and even more preferably from about 0.1 to 10 nm. According to some aspects, the pores may have an average pore diameter of from about 0.1 to 50 nm, preferably from about 10 to 40 nm, and even more preferably from about 20 to 30 nm.

[0034] According to some aspects, the pores may have a pore diameter in the range of about 0.0001 to 50 μm, preferably in the range of about 0.0001 to 10 μm, and more preferably in the range of about 0.0001 μm to 5 μm. According to some aspects, the pores may have an average pore diameter from about 0.1 to 20 μm, preferably from about 0.1 to 10 μm, more preferably from about 0.1 μm to 7 μm, and even more preferably from about 0.5 μm to 4 μm. According to some aspects, the pores may have an average pore diameter from about 0.1 to 50 nm, preferably from about 0.1 to 40 nm, more preferably from about 0.1 to 30 nm, even more preferably from about 0.1 to 20 nm, and most preferably from about 1 to 10 nm. In a non-limiting example, the average pore diameter is based on a Brunauer-Emmett-Teller (BET) measurement.

[0035] According to some aspects, the pores may have a pore volume of from about 10.sup.−24 to 10.sup.−6 liters.

[0036] According to some aspects, the volume of the pores in the porous metal substrate may be in the range of about 0.00001 to 0.00040 cm.sup.3/g, preferably in the range of about 0.00001 to 0.00030 cm.sup.3/g, and more preferably in the range of about 0.00002 to 0.00020 cm.sup.3/g. According to some aspects, the average volume of the pores in the porous metal substrate may be from about 0.0001 to about 1.0 cm.sup.3/g, preferably from about 0.0001 to 0.1 cm.sup.3/g, more preferably from about 0.0001 to about 0.01 cm.sup.3/g, and even more preferably from about 0.001 to about 0.01 cm.sup.3/g.

[0037] According to some aspects, the porous metal substrate may have a specific surface area of from about less than 1 m.sup.2/g to more than 100 m.sup.2/g. For example, according to some aspects, the porous metal substrate may have a specific surface area of from about 0.01 to 20 m.sup.2/g, preferably from about 0.1 to 15 m.sup.2/g, more preferably from about 1.0 to 10 m.sup.2/g, and even more preferably from about 1.0 to 6.0 m.sup.2/g.

[0038] According to some aspects, the porous metal substrate may have a density of from about 1 to 10.sup.3 kg/m.sup.3. According to some aspects, the pore size distribution may range from micro to meso to macro, and may be either monomodal, bimodal, or multimodal (i.e., may comprise one or more different distribution of pore sizes). According to some aspects, the porous metal substrate may have a pore distribution from nanometers up to millimeters. According to some aspects, the pores may have a pore length from a few nanometers up to several centimeters.

[0039] FIGS. 11a-11d show the results of Brunauer-Emmett-Teller (BET) surface area measurements corresponding to an example porous hard carbon material according to aspects of the present disclosure. Specifically, FIGS. 11a-11d correspond to material that is similar to the material disclosed in U.S. Patent Application Publication No. 2007/0287068, that is, an anode formed from a pitch-based hard carbon having an average particle size of preferably between 5 and 15 μm, a surface area of between 0.5 and 15 m.sup.2/g, an interlayer spacing d.sub.002 of between 0.355 and 0.400 nm, and a density of between 1.50 and 1.60 g/cm.sup.3. The anode may be formed by mixing the hard carbon material with polyvinylidene to form a paste together with N-methyl-2-pyrrolidore, which may then be applied to a copper foil, dried, and then pressed to provide the electrode.

[0040] It should thus be understood that FIGS. 11a-11d show measurements that are similar to or the same as measurements corresponding to the porous metal substrate of the present disclosure, as the porous metal substrate of the present disclosure may comprise a pore size, pore volume, surface area, density, pore size distribution, and/or pore length similar to that of hard carbon.

[0041] As can be seen, for example, in FIG. 11a, the adsorption average pore diameter was found to be about 6.76 nm, and the Barrett-Joyner-Halenda (BJH) adsorption average pore diameter was found to be about 27.95 nm or about 25.56 nm. FIGS. 12a and 12b show mercury porosity measurements corresponding to an example hard carbon material according to the present disclosure. As can be seen by these figures, the hard carbon material showed a pore size distribution with a peak ranging from about 0.5 to 4 μm pore diameter, with multiple peaks ranging from about 0.1 to 20 nm.

[0042] According to some aspects, the component may have a specific capacity in an electrochemical battery, such as an LIB, that is greater than that of graphene. For example, the component may have a specific capacity in an LIB greater than about 350 Ah/kg, alternatively greater than 400 Ah/kg, alternatively greater than about 425 Ah/kg. According to some aspects, the component may have a specific capacity in an electrochemical battery that is equal to or greater than the specific capacity of hard carbon in an electrochemical battery. For example, the component may have a specific capacity in an electrochemical battery that is equal to or greater than about 450 Ah/kg. According to some aspects, the specific capacity of the component in an electrochemical battery may also be less than 350 Ah/kg. For example, according to some aspects, the component may comprise a porous metal substrate without an additional material (e.g., a current collector) thereby rendering a net capacity of less than 350 Ah/kg sufficient for use according to the present disclosure.

[0043] According to some aspects, the component may be comprised of an electrically conductive porous metal substrate capable of collecting electric charge, for example, a metal. Examples of metals useful in the present disclosure include copper, nickel, platinum, aluminum, and mixtures and/or alloys thereof, among others. According to some aspects, the electrically conductive porous metal substrate comprises copper. Copper is used in anode materials for electrochemical batteries due to a number of benefits, including a higher density than graphite, low cost, high abundance, and environmental impact.

[0044] According to some aspects, the electrically conductive porous metal substrate may comprise other metals, including iron, nickel, platinum, aluminum, silver, gold, palladium, iridium, rhodium, ruthenium, osmium, rhenium, titanium, niobium, tantalum, and mixtures and/or alloys thereof, among others. According to some aspects, the component may be capable of both ion (e.g., lithium ion) insertion and extraction in addition to current collection, and thus may be capable of acting as both an electrode (e.g., an anode) and a current collector in an electrochemical battery. As used herein, the term “current collector” refers to a part of an electrochemical battery that provides an electrical connection in order to facilitate the flow of electricity. As used herein, the term “anode” refers to the negative electrode in an electrochemical battery.

[0045] According to some aspects, the porous metal substrate may comprise a plurality of metal nanoparticles which have been compressed together, or otherwise solidified. As used herein, the term “nanoparticle” refers to any microscopic particle that is measured on the nanoscale, including a nanosphere. According to some aspects, the porous metal substrate may comprise a plurality of nanoparticles which have been sintered. According to some aspects, the nanoparticles may be compacted by solid state sintering, wherein a powder of the nanoparticles are bonded together into a mass by applying heat. For example, nanoparticles may be placed into a mold or die, and subjected to high heat in a non-oxidizing atmosphere, wherein the resultant component is a mass with pores therein. As used herein, a “non-oxidizing atmosphere” refers to an atmosphere in which the material comprised in the nanoparticles is not oxidized, including an inert atmosphere and a reducing atmosphere. According to some aspects, compression of the nanoparticles is terminated before the nanoparticles are completely fused, thereby forming pores in the resultant metal substrate by leaving some space between the compressed nanoparticles. According to some aspects, the sintering temperature may range from 30° C. up to 1000° C. According to some aspects, the sintering time may range from a few minutes up to tens of hours. According to some aspects, the porous metal substrate may be a self-supporting mass. As used herein, a “self-supporting mass” relates to a mass which is not deposited or mounted on a support prior to its incorporation in an electrochemical battery.

[0046] For example, as shown in FIG. 1, the porous metal substrate may be manufactured using a plurality of nanoparticles (1) which are sintered to form a solid mass (2) with pores (3) therein. For example, the pores may result from the space between the nanoparticles prior to sintering. In a non-limiting example, the nanoparticles are copper nanoparticles. During sintering, the copper nanoparticles are held in a mold under pressure and the temperature is increased to a temperature below the melting point of the copper nanoparticles so that the atoms in the copper nanoparticles diffuse across the boundaries of the copper nanoparticles to bond the copper nanoparticles to form the porous metal substrate. The size of the resulting pores can be tailored by selecting a specific diameter of nanoparticles or metal particle precursor, as well as the operating conditions during the sintering process (e.g., temperature, pressure, residence time in the mold). Accordingly, a particular metal nanoparticle diameter or metal precursor can be selected that can produce a porous metal substrate with a pore size distribution similar to that of hard carbon. Variation of the metal nanoparticle size allows for varying the pore size and its distribution to obtain improved Li capacity without (or with reduced) dendrite formation in analogy with hard carbon.

[0047] According to some aspects, the nanoparticles used for making the porous metal substrate may have a size in the nanometer range. For example, the nanoparticles may have a diameter such that when the nanoparticles are compacted together, the resultant mass comprises pores which have a pore size and distribution as disclosed herein. According to some aspects, the porous metal substrate may comprise a plurality of compacted nanoparticles with uniform size, while according to other aspects, the porous metal substrate may comprise a plurality of compacted nanoparticles with various sizes. According to some aspects, at the porous metal substrate's specific capacity, the plurality of pores may be capable of ion (e.g., lithium ion) insertion and extraction without the formation of dendrites.

[0048] According to some aspects, the porous metal substrate may be a metal foam formed by heating or sintering a metal precursor. The metal precursor may be a metal salt, such as copper (II) sulphate pentahydrate and may be heated with an additive, such as dextran gel, in an oven to 600° C. in the presence of air to for example, hydrate the gel, burn off the dextran, and oxidize the metal salt to form a metal oxide monolith. The resulting metal oxide foam may be placed in an oven and exposed to hydrogen at a temperature of 1000° C. to convert the metal oxide foam to a metal foam.

[0049] According to some aspects, the porous metal substrate may be prepared by a dealloying process. According to some aspects, the porous metal substrate may be a monolithic structure prepared by a chemical dealloying process and/or an electrochemical dealloying process.

[0050] For example, according to some aspects, the porous metal substrate may be prepared using a chemical dealloying process wherein a metal alloy comprising at least a first metal component and a second metal component may be exposed to a selectively corrosive component such that at least the second component is leached from the alloy, thereby providing a porous metal substrate comprising the first component.

[0051] For example, according to some aspects, Mg—Cu alloy ingots may be prepared, and then melted (for example, by high-frequency induction heating) prior to melt-spinning onto a roller (for example, a copper roller) to obtain alloy ribbons. The resultant ribbons may then be exposed to an HCl solution (for example, a 1 wt. % HCl aqueous solution) for a certain period of time such that the Mg is dealloyed (or removed) from the sample. The sample may then be rinsed to provide a resultant porous copper substrate.

[0052] In another example, according to some aspects, an Mg—Cu alloy film may first be deposited on a solid foil (for example, a copper foil). The foil may then be exposed to an HCl solution (for example, a 10 mM HCl solution and deionized water that was first bubbled with N.sub.2 gas for 30 minutes) for a certain period of time such that the Mg is dealloyed (or removed) from the film. The residual acid may then be removed (for example, by rinsing with N.sub.2 bubbled water) from the film in order to provide a resultant porous copper substrate.

[0053] According to some aspects, the self-supporting metal substrate may comprise a porous metal first layer positioned on a non-porous metal second layer. In one example, according to some aspects, an alloy film containing copper and manganese may first be deposited on a solid foil (for example, a copper foil). The foil may then be exposed to an HCl solution (for example, a 10 mM HCl solution and deionized water that was first bubbled with N2 gas for 30 minutes) for a certain period of time such that the manganese is dealloyed (or removed) from the film. The residual acid may then be removed (for example, by rinsing with N2 bubbled water) from the film in order to provide the porous metal substrate comprising a porous copper layer on the copper foil. Accordingly the self-supporting copper substrate may comprise a porous copper layer positioned on a non-porous copper layer.

[0054] According to some aspects, when the self-supporting metal substrate comprises a porous metal first layer positioned on a non-porous metal second layer, the first layer and the second layer may have the same or different thicknesses, wherein thickness is defined as the distance between an outer surface of the first or second layer and the surface of the first or second layer abutting the other one of the first or second layer. For example, according to some aspects, the thickness of the porous metal first layer may be smaller than the thickness of the non-porous metal second layer. According to some aspects, the thickness of the porous metal first layer may be from about 400 to 1000 nm, optionally from about 500 to 900 nm, optionally from 600 to 800 nm, and optionally about 700 nm, while the thickness of the non-porous metal second layer may be from 0.01 to 20 μm, optionally from about 5 to 15 μm, and optionally about 10 μm.

[0055] According to some aspects, the non-porous metal second layer may be arranged such that it is towards the exterior of an electrochemical battery comprising the self-supporting metal substrate. For example, in an electrochemical battery comprising a separator positioned between a cathode and a component comprising the self-supporting metal substrate, the non-porous metal second layer may be arranged towards the exterior of the battery while the porous metal first layer may be arranged towards the separator.

[0056] According to some aspects, the porous metal substrate may be prepared using an electrochemical dealloying process, wherein a metal alloy comprising a at least a first metal component and a second metal component, the second metal component acting as an anode with respect to the first metal component, may be exposed to an electrolyte such that at least the second metal component is selectively dealloyed (or removed) due to galvanic corrosion, thereby providing a porous metal substrate comprising the first component.

[0057] For example, according to some aspects, an alloy (for example, a Cu—Si alloy) may be provided as a thin film on a substrate. The film may then be dealloyed by selectively dissolving, for example, silicon in an electrolyte using an externally applied voltage, thereby providing a resultant porous copper substrate.

[0058] According to some aspects, the component may comprise one or more materials in addition to the porous metal substrate. For example, according to some aspects, the porous metal substrate may be provided with one or more layers of one or more carbon-containing materials. Examples of carbon-containing materials include, but are not limited to, graphene, nanotubes, graphene oxide, graphite, graphite oxide, carbon fiber, fullerene, and combinations thereof. According to some aspects, the carbon-containing material may coat a portion or an entire outer surface of the porous metal substrate, wherein the structure of the substrate (e.g., the pore size) remains substantially the same as the uncoated porous metal substrate. That is, the carbon-containing material may be provided such that the structure of the porous metal substrate is maintained. In addition to, or alternatively, the internal portions of the porous metal substrate that define the pores may be coated with a carbon-containing material. For example, the porous metal substrate may include both a pore size or pore size distribution like that of hard carbon, and at least some of the internal portions of the porous metal substrate that define the pores may be coated with a carbon-containing material.

[0059] The carbon-containing material may be provided before, during, or after the production of the porous metal substrate. For example, according to some aspects, the carbon-containing material may be applied to (e.g., may coat) the nanoparticles to be used for making the porous metal substrate.

[0060] Alternatively or additionally, a carbon-containing precursor may be applied to (e.g., may coat) the nanoparticles, wherein the carbon-containing precursor may then be converted to the carbon-containing material. For example, a carbon-containing precursor (e.g., an organic material) may be applied to the nanoparticles and then decomposed to the carbon-containing material via pyrolysis.

[0061] According to some aspects, the carbon-containing material or the carbon-containing precursor may be applied via a method such as physical or chemical vapor deposition. For example, the nanoparticles to be used for making the porous metal substrate, or the porous metal substrate itself, may be placed inside a furnace under an inert atmosphere wherein they are heated (e.g., ramped up to 1000° C.) for a certain period of time (e.g., 50 minutes) and then exposed to hydrogen for another period of time (e.g., 20 minutes). The carbon-containing material or the carbon-containing precursor (e.g., methane gas) may then be introduced to the furnace in order to provide a coating of the carbon-containing material (e.g., graphene) on the nanoparticles, or the porous metal substrate itself. After the introduction of the carbon-containing material or the carbon-containing precursor, hydrogen may be introduced and the oven may be cooled. With respect to the nanoparticles, they may then be sintered, thereby producing a porous metal substrate coated with the carbon-containing material.

[0062] The present disclosure is also generally directed to electrochemical batteries, such as LIBs, comprising the component of the present disclosure described herein. For example, as shown in FIG. 2a, an LIB may comprise a cell (4) containing a nonaqueous liquid or a solid polymer electrolyte (5) which has a lithium salt dissolved therein capable of dissociating to lithium ions and an anion. Examples of lithium salts include lithium perchlorate, lithium borohexafluoride, and any other lithium salts soluble in the electrolyte. The LIB according to the present disclosure may also comprise a cathode (6) used in conventional LIBs, for example, comprising a positive active material mixed with the non-aqueous electrolyte, and optionally a binder and/or other additives. Examples of compounds useful in the positive active material include lithium cobalt oxide and lithium iron phosphate, or any other compounds known in the art. According to some aspects, the LIB may also comprise a current collector (7) in close proximity to the external face of the cathode (6), and a separator (8), for example, a perforated or microporous organic polymer membrane that allows the passage of lithium ions therethrough. According to some aspects, the component (the self-supporting porous metal substrate) (9) of the present disclosure may function in the LIB as both the anode and current collector. That is, according to some aspects, component (9) is the only anode material comprised in the LIB. According to some aspects, lithium ions may move from the component (9) to the cathode (6) via the electrolyte (5) during discharge while electrons, or electric current, flow from the component (9) to the cathode (6) through an outer circuit (10). According to some aspects, the lithium ions and the electrons may move in the opposite direction via the electrolyte (5) or through an outer circuit (10), respectively, when the LIB is recharging.

[0063] According to some aspects, the component (9) may comprise an outer layer which prevents unfavorable chemical interactions, for example, interactions between the porous metal substrate and an electrolyte in an electrochemical battery. For example, the porous metal substrate may comprise one or more layers of graphene thereon as shown in FIG. 2b. According to some aspects, one or more layers of graphene may be grown on and/or in the porous metal substrate by any means known in the art, for example, chemical vapor deposition.

[0064] The present disclosure is also directed to methods of making the components described herein. For example, aspects of the present disclosure comprise providing a plurality of metal nanoparticles, and subjecting the plurality of metal nanoparticles to high heat in a non-oxidizing atmosphere in order to sinter the nanoparticles thereby producing a metal substrate with pores therein. The plurality of nanoparticles may be provided, for example, in a powder. According to some aspects, the nanoparticles may be provided in a mold or die prior to heating. According to some aspects, the component may be shaped after the nanoparticles have been sintered.

[0065] According to some aspects, the present disclosure is directed to methods of producing the components described herein using a chemical dealloying process and/or an electrochemical dealloying process. For example, according to some aspects, a porous metal substrate may be prepared using a chemical and/or electrochemical dealloying process wherein at least a second metal component may be removed from an alloy comprising the second metal component and a first metal component, thereby providing a porous metal substrate comprising the first metal component.

[0066] While the aspects described herein have been described in conjunction with the example aspects outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the example aspects, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the disclosure. Therefore, the disclosure is intended to embrace all known or later-developed alternatives, modifications, variations, improvements, and/or substantial equivalents.

[0067] Thus, the claims are not intended to be limited to the aspects shown herein, but are to be accorded the full scope consistent with the language of the claims, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed as a means plus function unless the element is expressly recited using the phrase “means for.”

[0068] Further, the word “example” is used herein to mean “serving as an example, instance, or illustration.” Any aspect described herein as “example” is not necessarily to be construed as preferred or advantageous over other aspects. Unless specifically stated otherwise, the term “some” refers to one or more. Combinations such as “at least one of A, B, or C,” “at least one of A, B, and C,” and “A, B, C, or any combination thereof” include any combination of A, B, and/or C, and may include multiples of A, multiples of B, or multiples of C. Specifically, combinations such as “at least one of A, B, or C,” “at least one of A, B, and C,” and “A, B, C, or any combination thereof” may be A only, B only, C only, A and B, A and C, B and C, or A and B and C, where any such combinations may contain one or more member or members of A, B, or C. Nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims.

[0069] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the present disclosure, and are not intended to limit the scope of what the inventors regard as their disclosure nor are they intended to represent that the experiments below are all or the only experiments performed. Efforts have been made to ensure accuracy with respect to numbers used (e.g. amounts, dimensions, etc.) but some experimental errors and deviations should be accounted for.

EXAMPLE

[0070] The following study was conducted in order to compare components according to the present disclosure with a graphite electrode dispersed on a copper current collector.

[0071] Preparation and Function of a Battery with a Reference Electrode

[0072] As shown in FIG. 3, a coin cell battery comprising a conventional graphite cathode dispersed on a copper current collector was produced. Specifically, a coin cell battery type CR2332 having a voltage range of 0V-2.0V and comprising a Celgard PP film separator, 1M LiPF6 EC-DEC as an electrolyte, a Li 380 umt anode, and a graphite cathode was prepared. The electrodes were prepared using a hand printing method with 5% binder. The graphite electrode comprised the following parameters:

TABLE-US-00001 Electrode Diameter 1.4 cm Electrode Area 1.54 cm.sup.2 Surface Density 2.86 mg/cm.sup.2 Current Density 0.143 mA/cm.sup.2

[0073] The coin cell battery was discharged and recharged through three complete cycles. The graphite electrode showed a reversible capacity of about 340 mAh/g after three cycles. FIGS. 4a, 4b, 4c, and 4d illustrate performance characteristics of the reference electrode. The performance of the reference electrode indicates that both the electrode preparation process and the coil cell configuration worked properly.

[0074] Preparation and Function of a Battery with a Microporous Copper Electrode

[0075] As shown in FIG. 5, a coin cell battery comprising a component according to the present disclosure was produced. Specifically, a coin cell battery type CR2332 having a voltage range of 0V-2.0V and comprising a Celgard PP film separator, 1M LiPF6 EC-DEC as an electrolyte, a Li 380 umt anode, and a microporous copper cathode was prepared. A separate current collector was not included.

[0076] The microporous copper electrode was prepared using copper foam from MTI Corporation. The copper foam had a thickness of 1.6 mm, and a pore size of about 231 μm. The resultant microporous copper electrode comprised the following parameters:

TABLE-US-00002 Electrode Diameter 1.4 cm Electrode Area 1.54 cm.sup.2 Surface Density 35 mg/cm.sup.2 Current Density 0.01 mA/cm.sup.2 Thickness: 1.6 mm Pore Size about 231 μm (110 pores per inch)

[0077] The coin cell battery was discharged and recharged through three complete cycles. Using a scanning electron microscope (SEM), the surface of the microporous copper electrode was compared before and after the three cycles, as shown in FIG. 6. Specifically, FIG. 6 shows that there was no significant difference between the microporous copper electrode before (FIG. 6a) and after (FIG. 6b) testing, confirming that the microporous copper material was stable and suitable for use in an electrochemical battery.

[0078] However, as shown in FIGS. 7a and 7b, the microporous copper electrode showed a low capacity of about 1 mAh/g after three cycles of discharging and recharging. The additional performance characteristics of the coin cell battery are shown in FIGS. 7c and 7d. Irreversible capacity shown in the first cycle is likely due to SEI (solid-electrolyte interphase) formation. The Coulomb efficiency is very good, indicating a very reversible performance. The low capacity is likely due to an inefficient pore size (too large of a pore size for the electrode).

[0079] Preparation and Function of a Battery with a Nanoporous Copper Electrode

[0080] As shown in FIG. 8, a coin cell battery comprising a component according to the present disclosure was produced with a porous copper cathode comprising a smaller pore size. Specifically, a coin cell battery type CR2332 having a voltage range of 0V-2.0V and comprising a Celgard PP film separator, 1M LiPF6 EC-DEC as an electrolyte, a Li 380 umt anode, and a nanoporous copper cathode was prepared. No separate current collector was included.

[0081] The nanoporous copper electrode was prepared using nanoporous copper material from Jilin University. The material had a thickness of 700 nm, a pore size of about 50 nm, and was prepared using a chemical dealloying process substantially similar to the chemical dealloying processes described herein. The resultant nanoporous copper electrode comprised the following parameters:

TABLE-US-00003 Electrode Diameter 1.4 cm Electrode Area 1.54 cm.sup.2 Surface Density 0.21 mg/cm.sup.2 Current Density 0.01 mA/cm.sup.2 Thickness: 700 nm Pore Size about 50 nm

[0082] The coin cell battery was discharged and recharged through three complete cycles. Using a scanning electron microscope (SEM), the surface of the nanoporous copper electrode was compared before and after the three cycles, as shown in FIG. 9. Specifically, FIG. 9 shows that there was no significant difference between the nanoporous copper electrode before (FIG. 9a) and after (FIG. 9b) testing, confirming that the nanoporous copper material was stable and suitable for use in an electrochemical battery.

[0083] In addition, the capacity of the nanoporous copper electrode was measured after each of the three cycles of discharge or recharge, as shown in FIGS. 10a and 10b. For example, as shown in FIG. 10, the nanoporous copper electrode showed a capacity of about 23 mAh/g after three complete cycles, which is comparable to a typical carbon nanotube electrode and higher than the capacity of the microporous copper electrode after three complete cycles. This can also be seen in FIG. 10b, which shows electromotive force vs. capacity of the nanoporous copper electrode for the first (11), second (12), and third (13) discharge, and first (14), second (15), and third (16) recharge. Therefore, the nanoporous copper electrode was determined to be suitable for use in an electrochemical battery. In addition, it was determined that pore size affects the capacity of components comprising a porous metal substrate.

[0084] Therefore, the experiments establish that pure porous copper can act as both a current collector and an active electrode, thereby eliminating the need for a separate current collector. In addition, the distribution of porous copper has a substantial impact on Li storage capacity.