Abstract: Embodiments described herein generally relate to methods and apparatus for forming an electrode structure used in an energy storage device. More particularly, embodiments described herein relate to methods and apparatus for characterizing nanomaterials used in forming high capacity electrode structures for energy storage devices. In one embodiment a process for forming an electrode structure for an energy storage device is provided. The process comprises depositing a columnar metal structure over a substrate at a first current density by a diffusion limited deposition process, measuring a capacitance of the columnar metal structure to determine a surface area of the columnar metal structure, and depositing three dimensional porous metal structures over the columnar metal structure at a second current density greater than the first current density.

Abstract: A mesoporous carbon material formed on an electrode surface in an energy storage device, and a method of forming the same are disclosed. The mesoporous carbon material acts as a high surface area ion intercalation medium for the energy storage device, and is made up of CVD-deposited carbon fullerene “onions” and carbon nanotubes (CNTs) that are interconnected in a fullerene/CNT hybrid matrix. The fullerene/CNT hybrid matrix is a high porosity material that is capable of retaining lithium ions in concentrations useful for storing significant quantities of electrical energy. The method, according to one embodiment, includes vaporizing a high molecular weight hydrocarbon precursor and directing the vapor onto a conductive substrate to form a mesoporous carbon material thereon.

Abstract: A method and apparatus for forming a reliable and cost efficient battery or electrochemical capacitor electrode structure that has an improved lifetime, lower production costs, and improved process performance are provided. In one embodiment a method for forming a three dimensional porous electrode for a battery or an electrochemical cell is provided. The method comprises depositing a columnar metal layer over a substrate at a first current density by a diffusion limited deposition process and depositing three dimensional metal porous dendritic structures over the columnar metal layer at a second current density greater than the first current density.

Abstract: Anisotropic hydrophobic/hydrophilic nanoporous membranes and methods of forming anisotropic hydrophobic/hydrophilic nanoporous membranes are disclosed. The method of forming the nanoporous membrane includes growing a nanoporous oxide film on a substrate. A nanoporous membrane having a top side and a bottom side can then be formed by partially separating the nanoporous oxide film from the substrate. A fluorocarbon film can be deposited on the top side of the nanoporous membrane by plasma polymerization. The disclosed anisotropic hydrophobic/hydrophilic nanoporous membranes can have extremely different hydrophobicity between the top side and the bottom side of the nanoporous membrane.

Abstract: Method for depositing a metallic material on an aluminum alloy surface for galvanic displacement type deposition, electrodeposition or electroless deposition of a metallic film on the surface wherein the alloy surface is oxidized (e.g. anodized) to form aluminum oxide and the oxidized surface is etched to leave a partial thickness of a barier aluminum oxide on the alloy surface. The partial thickness of the barrier oxide is controlled by etching to form a porous, metallic particulate film for a thin barrier oxide, or a continuous metallic film for thicker barrier oxide. The metallic film then is electrodeposited or electroless deposited on the barrier film.

Abstract: Anisotropic hydrophobic/hydrophilic nanoporous membranes and methods of forming anisotropic hydrophobic/hydrophilic nanoporous membranes are disclosed. The method of forming the nanoporous membrane includes growing a nanoporous oxide film on a substrate. A nanoporous membrane having a top side and a bottom side can then be formed by partially separating the nanoporous oxide film from the substrate. A fluorocarbon film can be deposited on the top side of the nanoporous membrane by plasma polymerization. The disclosed anisotropic hydrophobic/hydrophilic nanoporous membranes can have extremely different hydrophobicity between the top side and the bottom side of the nanoporous membrane.

Abstract: Method for treating an aluminum alloy surface for electrodeposition or electroless deposition of a metal or alloy on the surface, the surface is oxidized (e.g. anodized) to form aluminum oxide, and then the oxidized surface is chemically etched to render the surface amenable for electrodeposition or electroless deposition of the metal or alloy thereon. A metallic coating can be electrodeposited or electroless deposited on the treated surface.