Particle-based silicon electrodes for energy storage devices

Patent metadata

Field	Value
Publication number	US-10217996-B2
Application number	US-201615340750-A
Country	US
Kind code	B2
Filing date	Nov 1, 2016
Priority date	Jun 28, 2013
Publication date	Feb 26, 2019
Grant date	Feb 26, 2019

Abstract

Electrodes, energy storage devices using such electrodes, and associated methods are disclosed. In an example, an electrode for use in an energy storage device can comprise porous disks comprising a porous material, the porous disks having a plurality of channels and a surface, the plurality of channels opening to the surface; and a structural material encapsulating the porous disks; where the structural material provides structural stability to the electrode during use.

First claim

What is claimed is:

1. An electrode comprising:
porous disks comprising a porous material, the porous disks having a surface with a plurality of channels opening to the surface; and
a structural material encapsulating the porous disks;
wherein the electrode does not include a polymer mixed with the porous disks.

2. The electrode of claim 1 , wherein the porous disks have a thickness and have at least one dimension selected from length, width, or radius that is twice (2×) the thickness.

3. The electrode of claim 1 , further comprising an ion containing electrolyte, wherein the ion has a higher diffusion rate in the structural material than in the porous material.

4. The electrode of claim 3 , wherein the higher diffusion rate in the structural material is an order of magnitude higher than the diffusion rate in the porous material.

5. The electrode of claim 3 , wherein the ion containing electrolyte comprises a lithium salt including lithium hexafluorophosphate (LiPF 6 ), lithium hexafluoroarsenate monohydrate (LiAsF 6 ), lithium perchlorate (LiClO 4 ), lithium tetrafluoroborate (LiBF 4 ), lithium triflate (LiCF 3 SO 3 ), or mixtures thereof.

6. The electrode of claim 1 , wherein the structural materials have a specific charge storage capacity of from about 5% to about 50% of the specific capacity of the porous particles.

7. The electrode of claim 1 , wherein the structural material is a carbon-based material.

8. The electrode of claim 7 , wherein the carbon-based material is selected from the group consisting of graphite, graphene, nanotubes, activated carbon, aerogels, and mixtures thereof.

9. The electrode of claim 1 , wherein the structural material is selected from the group consisting of germanium, tin, silicon carbide, titanium dioxide, and mixtures thereof.

10. The electrode of claim 1 , wherein the porous material is selected from the group of silicon, tin, germanium, SiGe, Si alloys, and titanium dioxide.

11. The electrode of claim 1 , wherein the porous material is silicon.

12. The electrode of claim 1 , wherein the porous disks comprise multi-layered carbon-silicon with a carbon core.

13. The electrode of claim 1 , further comprising a solid layer coated on the porous disks.

14. The electrode of claim 1 , wherein the porous particles have a porosity ranging from about 25% to about 80%.

15. An energy storage device comprising:
a first electrode comprising porous disks and an ion containing electrolyte, the porous disks embedded in a structural material, the porous disks comprising a porous material and having a surface with a plurality of channels opening to the surface;
wherein the electrode does not include a polymer mixed with the porous particles; and
wherein the ion has a higher diffusion rate in the structural material than in the porous material.

16. The energy storage device of claim 15 , wherein the porous material is silicon.

17. The energy storage device of claim 15 , wherein the structural material is a carbon-based material selected from the group consisting of graphite, graphene, nanotubes, activated carbon, aerogels, and mixtures thereof.

18. The energy storage device of claim 15 , further comprising a second electrode wherein the first electrode is an anode.

19. A method of manufacturing an energy storage device, comprising:
providing a plurality of porous disks, the porous disks comprising a porous material, the porous material having a plurality of channels opening to a surface of the porous material, wherein the porous disks are provided by increasing porosity in discrete layers of a block of the porous material and subsequently breaking the discrete layers to form individual porous disks or by electropolishing discrete layers of the block of the porous material between each disk;
embedding the porous disks within a structural material forming embedded porous disks;
diffusing an ion from an ion containing electrolyte into the porous material through the structural material;
wherein the embedded porous disks and a structural material form a first electrode and wherein the ion has a higher diffusion rate in the structural material than in the porous material.

20. The method of claim 19 , further comprising etching a material using an acidic solution to provide the porous material.

21. The method of claim 19 , wherein the porous material is selected from the group consisting of silicon, tin, germanium, SiGe, Si alloys, titanium dioxide, and mixtures thereof; and
the structural material is selected from the group consisting of carbon, germanium, tin, silicon carbide, titanium oxide, and mixtures thereof.

22. The method of claim 19 , further comprising forming a solid layer on the surface of the porous material.

23. The method of claim 19 , wherein providing includes forming the porous disks by increasing porosity in discrete layers of a block of the porous material and subsequently breaking the discrete layers to form individual porous disks.

24. The electrode of claim 1 , wherein the porous disks are formed by increasing porosity in discrete layers of a block of the porous material and subsequently breaking the discrete layers to form individual porous disks or by electropolishing discrete layers of the block of the porous material between each disk.

25. The electrode of claim 1 , wherein the porous disks have a substantially uniform shape and size.

26. The electrode of claim 1 , wherein every channel in the porous disks opens to the surface.

27. The electrode of claim 1 , wherein some of the porous particles are entirely or partially surrounded by a void space in the structural material.

Assignees

• Intel Corp

Inventors

• Gardner Donald S
• Holzwarth Charles W
• Moon Bum Ki
• Liu Yang
• Pande Priyanka
• Murali Shanthi
• Cirigliano Nicolas
• Chen Zhaohui

Classifications

• Y02P70/54

  Cross-Sectional Technologies · mapped topic

• Y10T29/49108

  Electric battery cell making · CPC title

• H01M2004/027

  Negative electrodes · CPC title

• H01M4/483

  for non-aqueous cells (H01M4/485 takes precedence) · CPC title

• H01M4/366 Primary

  as layered products · CPC title