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).
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Patent number: 11069888Abstract: 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: GrantFiled: January 4, 2017Date of Patent: July 20, 2021Assignee: APPLIED MATERIALS, INC.Inventors: Gao Liu, Sergey D. Lopatin, Eric H. Liu, Ajey M. Joshi, Guo Ai, Zhihui Wang, Hui Zhao, Donghai Wang
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Publication number: 20190013513Abstract: 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: ApplicationFiled: January 4, 2017Publication date: January 10, 2019Inventors: Gao LIU, Sergey D. LOPATIN, Eric H. LIU, Ajey M. JOSHI, Guo AI, Zhihui WANG, Hui ZHAO, Donghai WANG
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Patent number: 9761882Abstract: 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: GrantFiled: February 27, 2017Date of Patent: September 12, 2017Assignee: APPLIED MATERIALS, INC.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Eric H. Liu, Robert Z. Bachrach, Connie P. Wang
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Publication number: 20170237074Abstract: 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: ApplicationFiled: February 27, 2017Publication date: August 17, 2017Inventors: Sergey D. LOPATIN, Dmitri A. BREVNOV, Eric H. LIU, Robert Z. BACHRACH, Connie P. WANG
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Patent number: 9583770Abstract: 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: GrantFiled: January 18, 2016Date of Patent: February 28, 2017Assignee: APPLIED MATERIALS, INC.Inventors: Sergey D. Lopatin, Dimitri A. Brevnov, Eric H. Liu, Robert Z. Bachrach, Connie P. Wang
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Patent number: 9567683Abstract: 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: GrantFiled: June 1, 2012Date of Patent: February 14, 2017Assignee: Applied Materials, Inc.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Robert Z. Bachrach
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Publication number: 20160226070Abstract: 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: ApplicationFiled: January 18, 2016Publication date: August 4, 2016Inventors: SERGEY D. LOPATIN, DIMITRI A. BREVNOV, ERIC H. LIU, ROBERT Z. BACHRACH, CONNIE P. WANG
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Patent number: 9240585Abstract: 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: GrantFiled: February 28, 2012Date of Patent: January 19, 2016Assignee: APPLIED MATERIALS, INC.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Eric H. Liu, Robert Z. Bachrach, Connie P. Wang
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Patent number: 9070944Abstract: 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: GrantFiled: August 10, 2012Date of Patent: June 30, 2015Assignee: APPLIED MATERIALS, INC.Inventors: Lu Yang, Josef T. Hoog, Miaojun Wang, Dongli Zeng, Robert Z. Bachrach, Hooman Bolandi, Sergey D. Lopatin
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Patent number: 8669011Abstract: 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: GrantFiled: June 3, 2013Date of Patent: March 11, 2014Assignee: Applied Materials, Inc.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Connie P. Wang, Robert Z. Bachrach
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Publication number: 20140011088Abstract: 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: ApplicationFiled: February 28, 2012Publication date: January 9, 2014Applicant: APPLIED MATERIALS, INC.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Eric H. Liu, Robert Z. Bachrach, Connie P. Wang
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Publication number: 20130260255Abstract: 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: ApplicationFiled: June 3, 2013Publication date: October 3, 2013Applicant: APPLIED MATERIALS, INC.Inventors: Sergey D. LOPATIN, Dmitri A. BREVNOV, Connie P. WANG, Robert Z. BACHRACH
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Patent number: 8546020Abstract: 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: GrantFiled: October 21, 2010Date of Patent: October 1, 2013Assignee: Applied Materials, Inc.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Connie P. Wang, Robert Z. Bachrach
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Publication number: 20130214200Abstract: 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: ApplicationFiled: August 10, 2012Publication date: August 22, 2013Applicant: Applied Materials, Inc.Inventors: Lu Yang, Josef T. Hoog, Miaojun Wang, Dongli Zeng, Robert Z. Bachrach, Hooman Bolandi, Sergey D. Lopatin
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Patent number: 8486562Abstract: 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: GrantFiled: June 30, 2009Date of Patent: July 16, 2013Assignee: Applied Materials, Inc.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Robert Z. Bachrach
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Publication number: 20120237823Abstract: 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: ApplicationFiled: June 1, 2012Publication date: September 20, 2012Applicant: Applied Materials, Inc.Inventors: SERGEY D. LOPATIN, Dmitri A. BREVNOV, Robert Z. BACHRACH
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Patent number: 8206569Abstract: 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: GrantFiled: January 29, 2010Date of Patent: June 26, 2012Assignee: Applied Materials, Inc.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Robert Z. Bachrach
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Patent number: 8192605Abstract: 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: GrantFiled: February 9, 2009Date of Patent: June 5, 2012Assignee: Applied Materials, Inc.Inventors: Sergey D. Lopatin, Dmitri A. Brevnov, Eric Casavant, Robert Z. Bachrach
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Publication number: 20120064225Abstract: 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: ApplicationFiled: September 13, 2010Publication date: March 15, 2012Applicant: APPLIED MATERIALS, INC.Inventors: Robert Z. Bachrach, Connie P. Wang, Sergey D. Lopatin, Hooman Bolandi, Ruben Babayants, Karl M. Brown, Michael C. Kutney
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Publication number: 20110217585Abstract: 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: ApplicationFiled: September 30, 2010Publication date: September 8, 2011Applicant: APPLIED MATERIALS, INC.Inventors: Connie P. Wang, Robert Z. Bachrach, Sergey D. Lopatin, Donald J.K. Olgado, Michael C. Kutney, Zheng Wang