Multi-component intermetallic electrodes for lithium batteries

Abstract

Multi-component intermetallic negative electrodes prepared by electrochemical deposition for non-aqueous lithium cells and batteries are disclosed. More specifically, the invention relates to composite intermetallic electrodes comprising two or more compounds containing metallic or metaloid elements, at least one element of which can react with lithium to form binary, ternary, quaternary or higher order compounds, these compounds being in combination with one or more other metals that are essentially inactive toward lithium and act predominantly, but not necessarily exclusively, to the electronic conductivity of, and as current collection agent for, the electrode. The invention relates more specifically to negative electrode materials that provide an operating potential between 0.05 and 2.0 V vs. metallic lithium.

Specific embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . A negative electrode for a non-aqueous lithium cell comprising a multi-component material electrochemically deposited onto a porous metal foam current collector, the multi-component material containing a first component that comprises at least one metallic or metalloid element that can react with lithium to form a binary, ternary, quaternary or higher order compound, and a second component comprising one or more additional metallic element that does not readily react with lithium; wherein either (a) the first component comprises at least one element selected from the group consisting of Al, Ag, Mg, In, Pb, Sn, Sb, Zn and Si and the second component comprises at least one element selected from the group consisting of Ti, V, Fe, Mn, Ni, and Co; or (b) the first component comprises at least one element selected from the group consisting of Al, Ag, Mg, In, Pb, Zn and Si and the second component comprises at least one element selected from the group consisting of Ti, V, Fe, Mn, Ni, Co, and Cu. 
     
     
         2 . The electrode of  claim 1 , in which the multi-component material provides an operating potential of about 0.05 to about 2.0 V vs. metallic lithium. 
     
     
         3 . The electrode of  claim 1 , in which the electrochemically deposited components individually are crystalline to X-rays. 
     
     
         4 . The electrode of  claim 3 , in which the structures of the crystalline components are ordered. 
     
     
         5 . The electrode of  claim 3 , in which the structures of the crystalline components are partially disordered. 
     
     
         6 . The electrode of  claim 3 , in which the structures of the crystalline components are disordered. 
     
     
         7 . The electrode of  claim 1 , in which the electrochemically deposited components individually are poorly crystalline to X-rays. 
     
     
         8 . The electrode of  claim 7 , in which the structures of the poorly crystalline components are ordered. 
     
     
         9 . The electrode of  claim 7 , in which the structures of the poorly crystalline components are partially disordered. 
     
     
         10 . The electrode of  claim 7 , in which the structures of the poorly crystalline components are disordered. 
     
     
         11 . The electrode of  claim 1 , in which the electrochemically deposited components individually are amorphous to X-rays. 
     
     
         12 . The electrode of  claim 1 , in which the metal foam current collector comprises Cu, Ni, or a combination thereof. 
     
     
         13 . The electrode of  claim 1 , in which the metal foam current collector comprises Cu. 
     
     
         14 . The electrode of  claim 1 , in which the first and second components of the electrode material comprise primary particles, which on average, are less than about 1000 nm in size. 
     
     
         15 . The electrode of  claim 14 , in which the primary particles are, on average, less than about 500 nm in size. 
     
     
         16 . The electrode of  claim 14 , in which the primary particles are, on average, less than about 100 nm in size. 
     
     
         17 . An electrochemical cell comprising the negative electrode of  claim 1 , a positive electrode, and an electrolyte therebetween. 
     
     
         18 . A battery comprising a plurality of electrochemical cells of  claim 17  arranged in parallel, in series, or both.