US 12,275,067 B2
Fabrication of three-dimensional porous electrode
Hyeji Park, Seoul (KR); Hyelim Choi, Seoul (KR); and Heeman Choe, Walnut Creek, CA (US)
Assigned to CellMo Materials Innovation, Inc., Conroe, TX (US)
Filed by CellMo Materials Innovation, Inc., Berkeley, CA (US)
Filed on Feb. 2, 2021, as Appl. No. 17/165,832.
Application 17/165,832 is a continuation of application No. 15/215,519, filed on Jul. 20, 2016, granted, now 10,906,098.
Claims priority of provisional application 62/194,677, filed on Jul. 20, 2015.
Claims priority of provisional application 62/194,564, filed on Jul. 20, 2015.
Prior Publication US 2021/0178471 A1, Jun. 17, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B22F 3/10 (2006.01); B22D 15/00 (2006.01); B22D 21/00 (2006.01); B22D 25/00 (2006.01); B22F 3/11 (2006.01); B22F 3/22 (2006.01); B22F 3/24 (2006.01); B22F 5/10 (2006.01); H01M 4/04 (2006.01); H01M 4/13 (2010.01); H01M 4/134 (2010.01); H01M 4/38 (2006.01); H01M 4/66 (2006.01); H01M 4/80 (2006.01); H01M 10/0525 (2010.01); H01M 4/02 (2006.01); H01M 4/52 (2010.01)
CPC B22F 3/10 (2013.01) [B22D 15/00 (2013.01); B22D 21/005 (2013.01); B22D 25/005 (2013.01); B22F 3/1143 (2013.01); B22F 3/222 (2013.01); B22F 3/24 (2013.01); B22F 5/10 (2013.01); B22F 2003/242 (2013.01); B22F 2201/01 (2013.01); B22F 2201/03 (2013.01); B22F 2301/205 (2013.01); B22F 2301/35 (2013.01); B22F 2998/10 (2013.01); B22F 2999/00 (2013.01); C04B 2235/3232 (2013.01); H01M 2004/021 (2013.01); H01M 4/0404 (2013.01); H01M 4/0485 (2013.01); H01M 4/13 (2013.01); H01M 4/134 (2013.01); H01M 4/387 (2013.01); H01M 4/523 (2013.01); H01M 4/661 (2013.01); H01M 4/801 (2013.01); H01M 10/0525 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A method comprising:
placing a mold on a copper rod into liquid nitrogen and pouring a metal slurry in the mold;
freezing the metal slurry where metal particles are piled up and physically attached between growing ice crystals;
forming a porous green-body by drying the ice crystals of the frozen slurry at a first temperature, leaving pores in their places with physical attachment;
constructing a porous metal foam by reducing and sintering the porous green-body at a second high temperature under hydrogen atmosphere, wherein the second temperature is higher than the first temperature, and the sintering comprises:
presintering at from about 200 degrees Celsius to about 250 degrees Celsius for about 3 hours to about 5 hours and then sintering at from about 700 degrees Celsius to about 900 degrees Celsius from about 12 hours to about 16 hours in a tube furnace under from an about 4-percent to an about 6-percent hydrogen mixture gas; and
cutting the porous metal foam into a form of a thin layer to apply it as an electrode in a lithium-ion battery.