Nissan North America, Inc.

Jessica Weber

Nilesh Dale

Ying Liu

Xiaoguang Hao

Kan Huang

Kenzo Oshihara

A battery has a three dimensional electrode including a current collector, electron directing members, each electron directing member having a perimeter edge attached to a surface of the current collector with a polymer binder, the electron directing members extending from the surface of the current collector and configured to direct electron flow along a layered direction of the electrode, an active material layer on the current collector and a separator. The electron directing members extend into the active material layer and having a free end in spaced relation to the separator.

Three dimensional electrode having electron directing members and method of making the same

An electrode has a first active material layer between a current collector and a separator. The first active material layer comprises an active electrode material and electrically actuated fibers extending from a surface of the current collector and into the active electrode material. The electrically actuated fibers have an actuated state, in which the electrically actuated fibers change dimension in a linear direction under application of an electric field, the electrically actuated fibers configured to direct electrons through the active electrode material in a stacked direction of the electrode, and an unactuated state, in which the electrically actuated fibers are conductive but remain in an original state.

Electrode having electrically actuated fibers for electron conduction

An electrode comprising a current collector, a conductive buffer layer composed of a conductive polymer formed on the current collector, and an active material layer formed on the conductive buffer layer. The conductive buffer layer can expand and contract between the non-lithiated and lithiated states.

Electrode structure having structured conductive buffer layer

A method of making a three dimensional electrode having an active material layered between a current collector and a separator includes growing nanotubes at predetermined points on a first sheet of electron directing material, wherein the electron directing material is highly conductive and chemically inert; aligning the nanotubes in a direction perpendicular to the first sheet; functionalizing a distal end of each nanotube; bonding a second sheet of electron directing material to the functionalized distal end of each nanotube; depositing magnetic particles along the second sheet; applying a magnetic field to the magnetic particles to rotate the first sheet, the second sheet and the nanotubes ninety degrees to form an electron directing structure; and attaching the electron directing structure on a surface of the current collector with a polymer binder. The electron directing structure is configured to direct electron flow along a layered direction of the three dimensional electrode.

Electrodes made with a matrix selectively loaded with particular active particles provide uniform distribution and reduce issues due to particle expansion. The electrode has a current collector, a separator and a matrix having first pores having a first size and second pores having a second size, the first size being larger than the second size, the second pores being uniformly distributed throughout the matrix; first active particles deposited in the first pores, the first active particles having a first particle size smaller than the first pores and larger than the second pores; and second active particles deposited in the second pores, the second active particles having a second particle size smaller than the second pores.

Electrode having a selectively loaded matrix and method of manufacturing

An anode for a lithium-ion battery includes a current collector, a separator and an active material comprising alloying particles and a carbon material. A conductive net of carbon material surrounds the active material on at least the side walls and a separator-facing surface, the conductive net having net openings sized to retain the alloying particles and the carbon material within the conductive net while allowing lithium ions and electrons to pass through. The conductive net also maintains electrical contact between the carbon material and the alloying particles during lithiation and delithiation of the alloying particles.

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Berkley, MI, United States of America

Jessica Weber