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A meniscus brush plating electrodeposition technique was utilized in conjunction with a post deposition heat treatment to formulate freestanding copper-tin alloy films for negative electrodes of lithium-ion batteries. The described fabrication technique intertwined the electrode and current collector for improved cell volume utilization and stability. Two designs were examined to establish the best diffusivity to form electrochemically proficient copper-tin alloys. Fabrication was optimized to promote diffusion of copper and tin and to form the desired intermetallic phase of Cu6Sn5. This improved design fabricated films with competitive areal capacities above 1000 mAh/cc and 2.5 mAh/cm2 for the complete electrode and current collector structure.

The Fabrication of Freestanding Heterogeneous Copper-Tin Films with Meniscus Brush Plating Electrodeposition