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.

1 . A method for the synthesis of polymer electrodes comprising:
 a. providing a support comprising one or more conductive metal surfaces;   b. contacting the support with a solution in a first reaction zone comprising a monomer characterized by multiple oxidation states and capable of producing a conductive polymer in the presence of at least one electrode wherein the voltage potential of said electrode is altered between two or more voltage states, thereby initiating polymer growth, including PS, CV, PP or CC growth; and   c. sustaining polymer growth on the substrate in a second reaction zone wherein the voltage potential and/or current is maintained substantially constant.   
     
     
         2 . The method of  claim 1 , wherein the monomer is a substituted or unsubstituted pyrrole or aniline. 
     
     
         3 . The method of  claim 1 , wherein the monomer is aniline. 
     
     
         4 . The method of  claim 3 , wherein the solution is saturated with aniline. 
     
     
         5 . The method of  claim 1 , wherein the solution contains a strong acid. 
     
     
         6 . The method of  claim 5 , wherein the strong acid is a sulfonic acid. 
     
     
         7 . The method of  claim 1 , wherein the first and second reaction zones are in fluid communication, preferably in a single bath. 
     
     
         8 . The method of  claim 1 , wherein the conductive metal is aluminum or nickel. 
     
     
         9 . The method of  claim 1 , wherein conductive metal is layered on a non-conductive substrate, such as a polyester. 
     
     
         10 . The method of  claim 1 , wherein the voltage is altered during step (b). 
     
     
         11 . The method of  claim 1 , wherein current is pulsed in step (b). 
     
     
         12 . The method of  claim 1 , wherein the support is maintained in the solution of step (b) for less than 10 seconds. 
     
     
         13 . The method of  claim 1 , wherein a substantially constant voltage is maintained in step (c). 
     
     
         14 . The method of  claim 1 , wherein a substantially constant current is maintained in step (c). 
     
     
         15 . The method of  claim 1 , wherein the support is maintained in the solution of step (c) for at least about 1 minute. 
     
     
         16 . The method of  claim 1 , wherein the process is continuous. 
     
     
         17 . The method of  claim 1 , further comprising washing and drying the product of step (c). 
     
     
         18 . The method of  claim 1 , wherein the film is guided through the reaction zones using perforated guide rollers having a diameter substantially large than the thickness of the film and having a fluid discharged therefrom to maintain a fluid gap. 
     
     
         19 . The method of  claim 1 , the film is directed between at least one set of electrodes. 
     
     
         20 . The method of  claim 19 , wherein the film is directed between a plurality of sets of electrodes, wherein the electrodes are maintained under independent control. 
     
     
         21 . The method of  claim 20 , wherein the plurality of sets of electrodes are configured in a stacked configuration. 
     
     
         22 . The method of  claim 20 , further comprising the step of drying the film with at least two opposing infrared heat lamps. 
     
     
         23 . The method of  claim 22 , wherein the film is dried while applying a countercurrent drying gas. 
     
     
         24 . An electrode produced by the process of  claim 1 . 
     
     
         25 . A positive electrode characterized by a support comprising a conductive metal and conductive polymer nanowires having a diameter of less than about 500 nm, preferably less than about 200 nm. 
     
     
         26 . A positive electrode characterized by a support comprising a conductive metal and a conductive polymer disposed thereon having a surface area of at least about 200 m 2 /g, such as at least about 500 m 2 /g, or more preferably at least about 1000 m 2 /g. 
     
     
         27 . A semi-permeable separator membrane for use when stacking two or more products of the process of  claim 1  comprising:
 a. a semi-permeable polymer support membrane having essentially the same geometric shape as the product of the process of  claim 1 ; and 
 b. a plurality of periodic integrated pillars protrude at about a right angle from the support and extend at least about 1 micron above, the planar surface of the support membrane. 
 
     
     
         28 . (canceled)