Method for manufacturing anode components by atmospheric pressure plasma deposition, anode components, and lithium ion cells and batteries containing the components

摘要

Anode components for lithium-ion cells are formed using atmospheric plasma deposition. The anode component has a layer of anode material comprising high lithium-insertion capacity silicon particles as the active anode material in the pores of the bonded layer of metal particles. Atmospheric plasma deposition processes deposit metal particles and smaller silicon-containing particles simultaneously or sequentially on anode current collector substrates or polymer separator substrates for lithium-ion batteries. The layer of anode material may optionally be lithiated in an atmospheric pressure plasma deposition process. A plasma deposition process is used to form on a substrate a porous electrode layer consisting essentially of a porous metal matrix containing smaller particles of electrode material particles supported and carried within the pores of the matrix. When the anode component is assembled into a cell, the residual pore capacity is filled with a lithium-ion containing liquid electrolyte solution.