Patents by Inventor John C. Brewer

John C. Brewer has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20230343968
    Abstract: An anode for an energy storage device includes a current collector having an electrically conductive layer and a surface layer disposed over the electrically conductive layer. The surface layer may include a first surface sublayer proximate the electrically conductive layer and a second surface sublayer disposed over the first surface sublayer. The first surface sublayer may include zinc. The second surface sublayer may include a metal-oxygen compound, wherein the metal-oxygen compound includes a transition metal other than zinc. The current collector may be characterized by a surface roughness Ra ? 250 nm. The anode further includes a continuous porous lithium storage layer overlaying the surface layer. The continuous porous lithium storage layer may have an average thickness of at least 7 ┬Ám, may include at least 40 atomic % silicon, germanium, or a combination thereof, and may be substantially free of carbon-based binders.
    Type: Application
    Filed: June 28, 2021
    Publication date: October 26, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: John C. BREWER, Alexander J. WARREN, Kevin TANZIL, Paul D. GARMAN, Robert G. ANSTEY, Kyle P. POVLOCK
  • Publication number: 20230268511
    Abstract: An anode for an energy storage device includes a current collector having a metal oxide layer. A continuous porous lithium storage layer overlays the metal oxide layer, and a first supplemental layer overlays the continuous porous lithium storage layer. The continuous porous lithium storage layer may be substantially free of nanostructures. The continuous lithium storage layer may include amorphous silicon deposited by a PECVD process. The first supplemental layer includes silicon nitride, silicon dioxide, or silicon oxynitride. The anode may further include a second supplemental layer overlaying the first supplemental layer.
    Type: Application
    Filed: April 12, 2023
    Publication date: August 24, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: John C. Brewer, Kevin Tanzil, Paul D. Garman, Robert G. Anstey
  • Publication number: 20230216061
    Abstract: Methods of making an anode for a lithium-based energy storage device such as a lithium-ion battery are disclosed. Methods may include providing a current collector. The current collector may include an electrically conductive layer and a surface layer overlaying over the electrically conductive layer. The surface layer may have an average thickness of at least 0.002 ?m. The surface layer may include a metal chalcogenide including at least one of sulfur or selenium. Methods may include depositing a continuous porous lithium storage layer onto the surface layer by a PECVD process. The continuous porous lithium storage layer may have an average thickness in a range of 4 ?m to 30 ?m and comprises at least 85 atomic % amorphous silicon.
    Type: Application
    Filed: February 16, 2023
    Publication date: July 6, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: John C. Brewer, Paul D. Garman, Kevin Tanzil
  • Publication number: 20230207832
    Abstract: An anode for a lithium-based energy storage device such as a lithium-ion battery is disclosed. The anode includes an electrically conductive current collector comprising an electrically conductive layer and a transition metal oxide layer overlaying the electrically conductive layer. The anode may include a continuous porous lithium storage layer provided over the transition metal oxide layer. The continuous porous lithium storage layer may include at least 80 atomic % amorphous silicon and a silicide-forming metallic element in a range of 0.1 to 10 atomic %. A method of making the anode may include providing an electrically conductive current collector having an electrically conductive layer and a transition metal oxide layer provided over the electrically conductive layer. The transition metal oxide layer may have an average thickness of at least 0.05 ?m. A continuous porous lithium storage layer is deposited over the transition metal oxide layer by PECVD.
    Type: Application
    Filed: February 28, 2023
    Publication date: June 29, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: John C. Brewer, Kevin Tanzil, Paul D. Garman, Robert G. Anstey
  • Publication number: 20230207831
    Abstract: An anode for a lithium-based energy storage device such as a lithium-ion battery is disclosed. The anode includes an electrically conductive current collector comprising an electrically conductive layer and a transition metal oxide layer overlaying the electrically conductive layer. The anode may include a continuous porous lithium storage layer provided over the transition metal oxide layer. The continuous porous lithium storage layer may include at least 80 atomic % silicon. A method of making the anode may include providing an electrically conductive current collector having an electrically conductive layer and a transition metal oxide layer provided over the electrically conductive layer. A continuous porous lithium storage layer is deposited over the transition metal oxide layer by PECVD. The continuous porous lithium storage layer has a total content of silicon of at least 80 atomic %.
    Type: Application
    Filed: February 28, 2023
    Publication date: June 29, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: John C. Brewer, Kevin Tanzil, Paul D. Garman, Robert G. Anstey
  • Patent number: 11658300
    Abstract: An anode for an energy storage device includes a current collector having a metal oxide layer. A continuous porous lithium storage layer overlays the metal oxide layer, and a first supplemental layer overlays the continuous porous lithium storage layer. The first supplemental layer includes silicon nitride, silicon dioxide, or silicon oxynitride. The anode may further include a second supplemental layer overlaying the first supplemental layer. The second supplemental layer has a composition different from the first supplemental layer and may include silicon dioxide, silicon nitride, silicon oxynitride, or a metal compound.
    Type: Grant
    Filed: August 12, 2020
    Date of Patent: May 23, 2023
    Assignee: Graphenix Development, Inc.
    Inventors: John C. Brewer, Kevin Tanzil, Paul D. Garman, Robert G. Anstey
  • Publication number: 20230142782
    Abstract: An anode for an energy storage device includes a current collector having an electrically conductive layer that includes nickel or copper, and a lithium storage structure comprising a plurality of first microstructures in contact with the electrically conductive layer. Each first microstructure includes silicon and is characterized by a first maximum width measured across the widest section orthogonal to the first microstructure axis. Each first microstructure includes a first portion characterized by the width substantially tapering from the maximum width to a location where each first microstructure contacts the electrically conductive layer and a second portion positioned farther from the electrically conductive layer than the first portion, the second portion defining a substantially hemispherical shape and the top of each first microstructure. The lithium storage structure has at least 1 mg/cm2 of active silicon and a total atomic % of nickel and copper is from 0.5% to 1.2%.
    Type: Application
    Filed: April 7, 2021
    Publication date: May 11, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: John C. Brewer, Paul D. Garman, Robert G. Anstey, Kevin Tanzil
  • Patent number: 11631860
    Abstract: An anode for a lithium-based energy storage device such as a lithium-ion battery is disclosed. The anode includes an electrically conductive current collector comprising an electrically conductive layer and a transition metal oxide layer overlaying the electrically conductive layer. The anode may include a continuous porous lithium storage layer provided over the transition metal oxide layer. The continuous porous lithium storage layer may include at least 40 atomic % silicon. A method of making the anode may include providing an electrically conductive current collector having an electrically conductive layer and a transition metal oxide layer provided over the electrically conductive layer. The transition metal oxide layer may have an average thickness of at least 0.05 ?m. A continuous porous lithium storage layer is deposited over the transition metal oxide layer by PECVD.
    Type: Grant
    Filed: February 22, 2022
    Date of Patent: April 18, 2023
    Assignee: GRAPHENIX DEVELOPMENT, INC.
    Inventors: John C. Brewer, Kevin Tanzil, Paul D. Garman, Robert G. Anstey
  • Publication number: 20230063959
    Abstract: A prelithiated anode may include a current collector may include a metal oxide layer. Prelithiated anodes may in addition include a lithiated storage layer overlaying the metal oxide layer. The lithiated storage layer may be formed by incorporating lithium into a continuous porous lithium storage layer may include at least 80 atomic % silicon. The lithiated storage layer may include less than 1% by weight of carbon-based binders. The lithiated storage layer may further include lithium in a range of 1% to 90% of a theoretical lithium storage capacity of the continuous porous lithium storage layer. Batteries may include the prelithiated anode.
    Type: Application
    Filed: October 19, 2022
    Publication date: March 2, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: John C. Brewer, Kevin Tanzil, Paul D. Garman, Robert G. Anstey, Isaac N. Lund
  • Publication number: 20230050827
    Abstract: A lithium-ion battery may include a cathode, an anode, and a polymer electrolyte. The anode may include a current collector. The current collector may include a metal oxide layer provided in a first pattern overlaying a metal layer. The anode may also include a patterned lithium storage structure. The patterned lithium storage structure may include a continuous porous lithium storage layer overlaying at least a portion of the first pattern of metal oxide. These and other lithium-ion batteries are described.
    Type: Application
    Filed: October 27, 2022
    Publication date: February 16, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: Terrence R. O'Toole, John C. Brewer, Paul D. Garman, Robert G. Anstey
  • Publication number: 20230022169
    Abstract: An anode for an energy storage device includes a current collector. The current collector includes: i) an electrically conductive substrate including a first electrically conductive material; ii) a plurality of electrically conductive structures in electrical communication with the electrically conductive substrate, wherein each electrically conductive structure includes a second electrically conductive material; and iii) a metal oxide coating. The metal oxide coating includes one or both of: a) a first metal oxide material in contact with the electrically conductive substrate; or b) a second metal oxide material in contact with the electrically conductive structures; or both (a) and (b). The anode further includes lithium storage coating overlaying the metal oxide coating, the lithium storage layer including a total content of silicon, germanium, or a combination thereof. The electrically conductive structures are at least partially embedded within the lithium storage coating.
    Type: Application
    Filed: September 28, 2022
    Publication date: January 26, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: John C. Brewer, Terrence R. O'Toole
  • Publication number: 20230015866
    Abstract: An anode for use in an energy storage device is provided. The anode includes a current collector having an electrically conductive substrate and a surface layer overlaying a first side of the electrically conductive substrate. The surface layer may include a metal oxide or a metal chalcogenide. The anode may also include a lithium storage layer overlaying the surface layer. The lithium storage layer may have a total content of silicon, germanium, or a combination thereof of at least 40 atomic %. The lithium storage layer may include less than 10 atomic % carbon. The anode may also include a plurality of lithium storage filamentary structures in contact with a second side of the electrically conductive substrate. The second side is opposite the first side. The plurality of lithium storage filamentary structures may include silicon, germanium, tin, or a combination thereof.
    Type: Application
    Filed: September 29, 2022
    Publication date: January 19, 2023
    Applicant: Graphenix Development, Inc.
    Inventors: Terrence R. O'Toole, John C. Brewer
  • Publication number: 20230014638
    Abstract: A method of making an anode for an energy storage device such as a lithium-ion energy storage device is disclosed. The method may include depositing a first lithium storage layer over a current collector by a first CVD process. The current collector may include a metal oxide layer, and the first lithium storage layer is deposited onto the metal oxide layer. The method may also include forming a first intermediate layer over at least a portion of the first lithium storage layer. The method may further include depositing a second lithium storage layer over the first intermediate layer by a second CVD process. At least the first lithium storage layer may be a continuous porous lithium storage layer having a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %.
    Type: Application
    Filed: September 27, 2022
    Publication date: January 19, 2023
    Applicant: Graphenix Development, Inc.,
    Inventors: John C. Brewer, Paul D. Garman, Bernard Philip Gridley, Robert G. Anstey, Kevin Tanzil
  • Publication number: 20220376220
    Abstract: An anode for an energy storage device may include a current collector. The current collector may include a metal oxide layer. The metal oxide layer may include a doped oxide or zinc oxide. In addition, the anode may include a continuous porous lithium storage layer overlaying the metal oxide layer. The continuous porous lithium storage layer may include a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %.
    Type: Application
    Filed: July 26, 2022
    Publication date: November 24, 2022
    Applicant: Graphenix Development, Inc.
    Inventors: John C. Brewer, Kevin Tanzil, Paul D. Garman, Robert G. Anstey, Isaac N. Lund, Kyle P. Povlock
  • Patent number: 11508969
    Abstract: An anode for an energy storage device includes a current collector. The current collector includes: i) an electrically conductive substrate including a first electrically conductive material; ii) a plurality of electrically conductive structures in electrical communication with the electrically conductive substrate, wherein each electrically conductive structure includes a second electrically conductive material; and iii) a metal oxide coating. The metal oxide coating includes one or both of: a) a first metal oxide material in contact with the electrically conductive substrate; or b) a second metal oxide material in contact with the electrically conductive structures; or both (a) and (b). The anode further includes lithium storage coating overlaying the metal oxide coating, the lithium storage layer including a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %. The electrically conductive structures are at least partially embedded within the lithium storage coating.
    Type: Grant
    Filed: August 19, 2020
    Date of Patent: November 22, 2022
    Assignee: Graphenix Development, Inc.
    Inventors: John C. Brewer, Terrence R. O'Toole
  • Patent number: 11508965
    Abstract: A method of making a prelithiated anode for use in a lithium-ion battery includes providing a current collector having an electrically conductive layer and a metal oxide layer overlaying the electrically conductive layer. The metal oxide layer has an average thickness of at least 0.01 ?m. A continuous porous lithium storage layer is deposited onto the metal oxide layer by a CVD process. Lithium is incorporated into the continuous porous lithium storage layer to form a lithiated storage layer prior to a first electrochemical cycle when the anode is assembled into the battery. The anode may be incorporated into a lithium ion battery along with a cathode. The cathode may include sulfur or selenium and the anode may be prelithiated.
    Type: Grant
    Filed: August 12, 2020
    Date of Patent: November 22, 2022
    Assignee: Graphenix Development, Inc.
    Inventors: John C. Brewer, Kevin Tanzil, Paul D. Garman, Robert G. Anstey, Isaac N. Lund
  • Patent number: 11495782
    Abstract: A method of making an anode for use in an energy storage device is provided. The method includes providing a current collector having an electrically conductive substrate and a surface layer overlaying a first side of the electrically conductive substrate. A second side of the electrically conductive substrate includes a filament growth catalyst, wherein the second side is opposite the first. The method further includes depositing a lithium storage layer onto the surface layer using a first CVD process forming a plurality of lithium storage filamentary structures on the second side of the electrically conductive substrate using second CVD process.
    Type: Grant
    Filed: August 25, 2020
    Date of Patent: November 8, 2022
    Assignee: Graphenix Development, Inc.
    Inventors: Terrence R. O'Toole, John C. Brewer
  • Patent number: 11489155
    Abstract: An anode for an energy storage device includes a current collector having a metal layer; and a metal oxide layer provided in a first pattern overlaying the metal layer. The anode further includes a patterned lithium storage structure having a continuous porous lithium storage layer selectively overlaying at least a portion of the first pattern of metal oxide. A method of making an anode for use in an energy storage device includes providing a current collector having a metal layer and a metal oxide layer provided in a first pattern overlaying the metal layer. A continuous porous lithium storage layer is selectively formed by chemical vapor deposition by exposing the current collector to at least one lithium storage material precursor gas.
    Type: Grant
    Filed: April 22, 2021
    Date of Patent: November 1, 2022
    Assignee: Graphenix Development, Inc.
    Inventors: Terrence R. O'Toole, John C. Brewer, Paul D. Garman, Robert G. Anstey
  • Patent number: 11489154
    Abstract: An anode for an energy storage device such as a lithium-ion energy storage device is disclosed. The anode includes a current collector having a metal oxide layer, a first lithium storage layer overlaying the current collector, a first intermediate layer overlaying at least a portion of the first lithium storage layer, and a second lithium storage layer overlaying the first intermediate layer. The first lithium storage layer is a continuous porous lithium storage layer having a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %.
    Type: Grant
    Filed: August 19, 2020
    Date of Patent: November 1, 2022
    Assignee: Graphenix Development, Inc.
    Inventors: John C. Brewer, Paul D. Garman, Bernard Philip Gridley, Robert G. Anstey, Kevin Tanzil
  • Publication number: 20220344627
    Abstract: An anode for an energy storage device includes a current collector having an electrically conductive layer and a surface layer overlaying the electrically conductive layer. A lithium storage layer may overlay the surface layer. The surface layer may include manganese. The lithium storage layer may include at least 40 atomic % silicon, germanium, or a combination thereof.
    Type: Application
    Filed: April 21, 2022
    Publication date: October 27, 2022
    Applicant: Graphenix Development, Inc.
    Inventors: Alexander J. Warren, Peter G. Symons, John C. Brewer, Kyle P. Povlock, Kevin Tanzil, Robert G. Anstey, Paul D. Garman