Methods for producing textured electrode based energy storage device

Abstract

This method enables the use of nanowire or nano-textured forms of Polyaniline and other conductive polymers in energy storage components. The delicate nature of these very high surface area materials are preserved during the continuous electrochemical synthesis, drying, solvent application and physical assembly. The invention also relates to a negative electrode that is comprised of etched, lithiated aluminum that is safer and lighter weight than conventional carbon based lithium-ion negative electrodes. The invention provides for improved methods for making negative and positive electrodes and for energy storage devices containing them. The invention provides sufficient stability in organic solvent and electrolyte solutions, where the prior art processes commonly fail. The invention further provides stability during repetitive charge and discharge. The invention also provides for novel microstructure protecting support membranes to be used in an energy storage device.

What is claimed is: 
     
         1 . A method for making a lithiated electrode comprising lithiating an aluminum electrode wherein a reducing current is applied in a moisture free organic electrolyte solution comprising a lithium salt. 
     
     
         2 . The method of  claim 1 , wherein the aluminum electrode comprises a magnesium containing aluminum alloy. 
     
     
         3 . The method of  claim 1 , wherein the aluminum alloy comprises between 1 and 20 atom percent magnesium. 
     
     
         4 . The method of  claim 1 , wherein the aluminum alloy comprises at least 3 atom percent magnesium. 
     
     
         5 . The method of  claim 1 , wherein the reducing current is about 5 ma/cm 2 . 
     
     
         6 . The method of  claim 1 , wherein the lithium salt is selected from the group consisting of LiSO 4 , LiBF 4  and LiClO 4 . 
     
     
         7 . The method of  claim 1 , wherein the lithium salt is maintained in a concentration of at least about 0.5M. 
     
     
         8 . The method of  claim 1 , wherein the lithium salt is maintained in a concentration of at least about 1.0M. 
     
     
         9 . The method of  claim 1 , wherein the organic electrolyte solution comprises propylene carbonate and dimethoxyethane (PC/DME). 
     
     
         10 . The method of  claim 1 , wherein lithium is added to the aluminum electrode in an amount of about 5 and 30 atom percent. 
     
     
         11 . The method of  claim 1 , wherein the moisture conditions are less than −40 degrees dew point air. 
     
     
         12 . The method of  claim 1 , wherein the aluminum electrode is electrochemically etched prior to lithiation. 
     
     
         13 . The method of  claim 1 , wherein the electrochemical etching is achieved by adding a 1 M HCl, 5% ethylene glycol solution at room temperature with an oxidizing current. 
     
     
         14 . The method of  claim 1 , wherein the oxidizing current is at least 0.02 A/cm3.