Patents by Inventor Sergey D. Lopatin

Sergey D. Lopatin 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: 20190013513
    Abstract: A simple solution processing method is developed to achieve uniform and scalable stabilized lithium metal powder coating on Li-ion negative electrode. A solvent and binder system for stabilized lithium metal powder coating is developed, including the selection of solvent, polymer binder and enhancement of polymer concentration. The enhanced binder solution is 1% concentration of polymer binder in xylene, and the polymer binder is chosen as the mixture of poly(styrene-co-butadiene) rubber (SBR) and polystyrene (PS). Long-sustained, uniformly dispersed stabilized lithium metal powder suspension can be achieved with the enhanced binder solution. A uniform stabilized lithium metal powder coating can be achieved with simple doctor blade coating method and the resulting stabilized lithium metal powder coating can firmly glued on the anode surface.
    Type: Application
    Filed: January 4, 2017
    Publication date: January 10, 2019
    Inventors: Gao LIU, Sergey D. LOPATIN, Eric H. LIU, Ajey M. JOSHI, Guo AI, Zhihui WANG, Hui ZHAO, Donghai WANG
  • Patent number: 9761882
    Abstract: High capacity energy storage devices and energy storage device components, and more specifically, to a system and method for fabricating such high capacity energy storage devices and storage device components using processes that form three-dimensional porous structures are provided. In one embodiment, an anode structure for use in a high capacity energy storage device, comprising a conductive collector substrate, a three-dimensional copper-tin-iron porous conductive matrix formed on one or more surfaces of the conductive collector substrate, comprising a plurality of meso-porous structures formed over the conductive current collector, and an anodically active material deposited over the three-dimensional copper-tin-iron porous conductive matrix is provided.
    Type: Grant
    Filed: February 27, 2017
    Date of Patent: September 12, 2017
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Eric H. Liu, Robert Z. Bachrach, Connie P. Wang
  • Publication number: 20170237074
    Abstract: High capacity energy storage devices and energy storage device components, and more specifically, to a system and method for fabricating such high capacity energy storage devices and storage device components using processes that form three-dimensional porous structures are provided. In one embodiment, an anode structure for use in a high capacity energy storage device, comprising a conductive collector substrate, a three-dimensional copper-tin-iron porous conductive matrix formed on one or more surfaces of the conductive collector substrate, comprising a plurality of meso-porous structures formed over the conductive current collector, and an anodically active material deposited over the three-dimensional copper-tin-iron porous conductive matrix is provided.
    Type: Application
    Filed: February 27, 2017
    Publication date: August 17, 2017
    Inventors: Sergey D. LOPATIN, Dmitri A. BREVNOV, Eric H. LIU, Robert Z. BACHRACH, Connie P. WANG
  • Patent number: 9583770
    Abstract: High capacity energy storage devices and energy storage device components, and more specifically, to a system and method for fabricating such high capacity energy storage devices and storage device components using processes that form three-dimensional porous structures are provided. In one embodiment, an anode structure for use in a high capacity energy storage device, comprising a conductive collector substrate, a three-dimensional copper-tin-iron porous conductive matrix formed on one or more surfaces of the conductive collector substrate, comprising a plurality of meso-porous structures formed over the conductive current collector, and an anodically active material deposited over the three-dimensional copper-tin-iron porous conductive matrix is provided.
    Type: Grant
    Filed: January 18, 2016
    Date of Patent: February 28, 2017
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Sergey D. Lopatin, Dimitri A. Brevnov, Eric H. Liu, Robert Z. Bachrach, Connie P. Wang
  • Patent number: 9567683
    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.
    Type: Grant
    Filed: June 1, 2012
    Date of Patent: February 14, 2017
    Assignee: Applied Materials, Inc.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Robert Z. Bachrach
  • Publication number: 20160226070
    Abstract: High capacity energy storage devices and energy storage device components, and more specifically, to a system and method for fabricating such high capacity energy storage devices and storage device components using processes that form three-dimensional porous structures are provided. In one embodiment, an anode structure for use in a high capacity energy storage device, comprising a conductive collector substrate, a three-dimensional copper-tin-iron porous conductive matrix formed on one or more surfaces of the conductive collector substrate, comprising a plurality of meso-porous structures formed over the conductive current collector, and an anodically active material deposited over the three-dimensional copper-tin-iron porous conductive matrix is provided.
    Type: Application
    Filed: January 18, 2016
    Publication date: August 4, 2016
    Inventors: SERGEY D. LOPATIN, DIMITRI A. BREVNOV, ERIC H. LIU, ROBERT Z. BACHRACH, CONNIE P. WANG
  • Patent number: 9240585
    Abstract: High capacity energy storage devices and energy storage device components, and more specifically, to a system and method for fabricating such high capacity energy storage devices and storage device components using processes that form three-dimensional porous structures are provided. In one embodiment, an anode structure for use in a high capacity energy storage device, comprising a conductive collector substrate, a three-dimensional copper-tin-iron porous conductive matrix formed on one or more surfaces of the conductive collector substrate, comprising a plurality of meso-porous structures formed over the conductive current collector, and an anodically active material deposited over the three-dimensional copper-tin-iron porous conductive matrix is provided.
    Type: Grant
    Filed: February 28, 2012
    Date of Patent: January 19, 2016
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Eric H. Liu, Robert Z. Bachrach, Connie P. Wang
  • Patent number: 9070944
    Abstract: Apparatus and methods of forming a battery-active material are described. An apparatus includes a first processing section that raises the temperature of a precursor material to a reaction threshold temperature, a second processing section that converts the precursor material to a battery-active material, and a third processing section that cools the resulting battery-active material. Each of the processing sections may be a continuous flow tubular component. The first and third processing sections may be metal, and the second processing section may be a refractory material for high temperature service. The battery-active material is collected using a solids collector.
    Type: Grant
    Filed: August 10, 2012
    Date of Patent: June 30, 2015
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Lu Yang, Josef T. Hoog, Miaojun Wang, Dongli Zeng, Robert Z. Bachrach, Hooman Bolandi, Sergey D. Lopatin
  • Patent number: 8669011
    Abstract: Embodiments of the present invention generally relate to lithium-ion batteries, and more specifically, to a system and method for fabricating such batteries using thin-film processes that form three-dimensional structures. In one embodiment, an anodic structure used to form an energy storage device is provided. The anodic structure comprises a flexible conductive substrate, a plurality of conductive microstructures formed on the conductive substrate, comprising a plurality of columnar projections and dendritic structures formed over the plurality of columnar projections and a plurality of tin particles formed on the plurality of conductive microstructures. In another embodiment, the anodic structure further comprises a tin nucleation layer comprising tin particles formed on the flexible conductive substrate between the flexible conductive substrate and the plurality of conductive microstructures.
    Type: Grant
    Filed: June 3, 2013
    Date of Patent: March 11, 2014
    Assignee: Applied Materials, Inc.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Connie P. Wang, Robert Z. Bachrach
  • Publication number: 20140011088
    Abstract: High capacity energy storage devices and energy storage device components, and more specifically, to a system and method for fabricating such high capacity energy storage devices and storage device components using processes that form three-dimensional porous structures are provided. In one embodiment, an anode structure for use in a high capacity energy storage device, comprising a conductive collector substrate, a three-dimensional copper-tin-iron porous conductive matrix formed on one or more surfaces of the conductive collector substrate, comprising a plurality of meso-porous structures formed over the conductive current collector, and an anodically active material deposited over the three-dimensional copper-tin-iron porous conductive matrix is provided.
    Type: Application
    Filed: February 28, 2012
    Publication date: January 9, 2014
    Applicant: APPLIED MATERIALS, INC.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Eric H. Liu, Robert Z. Bachrach, Connie P. Wang
  • Publication number: 20130260255
    Abstract: Embodiments of the present invention generally relate to lithium-ion batteries, and more specifically, to a system and method for fabricating such batteries using thin-film processes that form three-dimensional structures. In one embodiment, an anodic structure used to form an energy storage device is provided. The anodic structure comprises a flexible conductive substrate, a plurality of conductive microstructures formed on the conductive substrate, comprising a plurality of columnar projections and dendritic structures formed over the plurality of columnar projections and a plurality of tin particles formed on the plurality of conductive microstructures. In another embodiment, the anodic structure further comprises a tin nucleation layer comprising tin particles formed on the flexible conductive substrate between the flexible conductive substrate and the plurality of conductive microstructures.
    Type: Application
    Filed: June 3, 2013
    Publication date: October 3, 2013
    Applicant: APPLIED MATERIALS, INC.
    Inventors: Sergey D. LOPATIN, Dmitri A. BREVNOV, Connie P. WANG, Robert Z. BACHRACH
  • Patent number: 8546020
    Abstract: Embodiments of the present invention generally relate to lithium-ion batteries, and more specifically, to a system and method for fabricating such batteries using thin-film processes that form three-dimensional structures. In one embodiment, an anodic structure used to form an energy storage device is provided. The anodic structure comprises a flexible conductive substrate, a plurality of conductive microstructures formed on the conductive substrate, comprising a plurality of columnar projections and dendritic structures formed over the plurality of columnar projections and a plurality of tin particles formed on the plurality of conductive microstructures. In another embodiment, the anodic structure further comprises a tin nucleation layer comprising tin particles formed on the flexible conductive substrate between the flexible conductive substrate and the plurality of conductive microstructures.
    Type: Grant
    Filed: October 21, 2010
    Date of Patent: October 1, 2013
    Assignee: Applied Materials, Inc.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Connie P. Wang, Robert Z. Bachrach
  • Publication number: 20130214200
    Abstract: Apparatus and methods of forming a battery-active material are described. An apparatus includes a first processing section that raises the temperature of a precursor material to a reaction threshold temperature, a second processing section that converts the precursor material to a battery-active material, and a third processing section that cools the resulting battery-active material. Each of the processing sections may be a continuous flow tubular component. The first and third processing sections may be metal, and the second processing section may be a refractory material for high temperature service. The battery-active material is collected using a solids collector.
    Type: Application
    Filed: August 10, 2012
    Publication date: August 22, 2013
    Applicant: Applied Materials, Inc.
    Inventors: Lu Yang, Josef T. Hoog, Miaojun Wang, Dongli Zeng, Robert Z. Bachrach, Hooman Bolandi, Sergey D. Lopatin
  • Patent number: 8486562
    Abstract: A method for forming a battery from via thin-film deposition processes is disclosed. A mesoporous carbon material is deposited onto a surface of a conductive substrate that has high surface area, conductive micro-structures formed thereon. A porous, dielectric separator layer is then deposited on the layer of mesoporous carbon material to form a half cell of an energy storage device. The mesoporous carbon material is made up of CVD-deposited carbon fullerene “onions” and carbon nano-tubes, and has a high porosity capable of retaining lithium ions in concentrations useful for storing significant quantities of electrical energy. Embodiments of the invention further provide for the formation of an electrode having a high surface area conductive region that is useful in a battery structure.
    Type: Grant
    Filed: June 30, 2009
    Date of Patent: July 16, 2013
    Assignee: Applied Materials, Inc.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Robert Z. Bachrach
  • Publication number: 20120237823
    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.
    Type: Application
    Filed: June 1, 2012
    Publication date: September 20, 2012
    Applicant: Applied Materials, Inc.
    Inventors: SERGEY D. LOPATIN, Dmitri A. BREVNOV, Robert Z. BACHRACH
  • Patent number: 8206569
    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.
    Type: Grant
    Filed: January 29, 2010
    Date of Patent: June 26, 2012
    Assignee: Applied Materials, Inc.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Robert Z. Bachrach
  • Patent number: 8192605
    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.
    Type: Grant
    Filed: February 9, 2009
    Date of Patent: June 5, 2012
    Assignee: Applied Materials, Inc.
    Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Eric Casavant, Robert Z. Bachrach
  • Publication number: 20120064225
    Abstract: In one embodiment, an apparatus for simultaneously depositing an anodically or cathodically active material on opposing sides of a flexible conductive substrate is provided. The apparatus comprises a chamber body defining one or more processing regions in which a flexible conductive substrate is exposed to a dual sided spray deposition process, wherein each of the one or more processing regions are further divided into a first spray deposition region and a second spray deposition region for simultaneously spraying an anodically active or cathodically active material onto opposing sides of a portion of the flexible conductive substrate, wherein each of the first and second spray deposition regions comprise a spray dispenser cartridge for delivering the activated material toward the flexible conductive substrate and a movable collection shutter.
    Type: Application
    Filed: September 13, 2010
    Publication date: March 15, 2012
    Applicant: APPLIED MATERIALS, INC.
    Inventors: Robert Z. Bachrach, Connie P. Wang, Sergey D. Lopatin, Hooman Bolandi, Ruben Babayants, Karl M. Brown, Michael C. Kutney
  • Publication number: 20110217585
    Abstract: Embodiments of the present invention relate generally to lithium-ion batteries, and more specifically, to batteries having integrated separators and methods of fabricating such batteries. In one embodiment, a lithium-ion battery having an electrode structure is provided. The lithium-ion battery comprises an anode stack, a cathode stack, and an integrated separator formed between the anode stack and the cathode stack. The anode stack comprises an anodic current collector and an anode structure formed over a first surface of the anodic current collector. The cathode stack comprises a cathodic current collector and a cathode structure formed over a first surface of the cathodic current collector. The integrated separator comprises a first ceramic layer, a second ceramic layer, and a polymer material layer deposited between the first ceramic layer and the second ceramic layer.
    Type: Application
    Filed: September 30, 2010
    Publication date: September 8, 2011
    Applicant: APPLIED MATERIALS, INC.
    Inventors: Connie P. Wang, Robert Z. Bachrach, Sergey D. Lopatin, Donald J.K. Olgado, Michael C. Kutney, Zheng Wang
  • Publication number: 20110200881
    Abstract: A method for forming an electrode for a battery is disclosed. The method includes providing a substrate. A plurality of clusters of lithium containing compound is formed over the substrate, with each cluster having a plurality of sub-structures of lithium containing compound that exhibit nanocrystalline structure. The plurality of sub-structures of lithium containing compound are transformed to exhibit cation ordering structure. In some embodiments, a protective layer is disposed over the cluster of Li containing compound. An electrode for a battery and a system for processing the substrate are also disclosed.
    Type: Application
    Filed: February 8, 2011
    Publication date: August 18, 2011
    Inventors: Connie P. Wang, Sergey D. Lopatin, Robert Z. Bacharach