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

摘要

The anode component for a lithium-ion cell is formed using atmospheric plasma deposition. The anode component has an anode material layer comprising high lithium-insertion capacity silicon particles as the active anode material in the pores of the combined layer of metal particles. The atmospheric plasma deposition process deposits metal particles and smaller silicon-containing particles simultaneously or sequentially on an anode current collector substrate or polymer separator substrate for a lithium-ion battery. The anode material layer may optionally be lithiated in an atmospheric plasma deposition process. The plasma deposition process is used to form a porous electrode layer on a substrate 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.