Materials with extremely durable intercalation of lithium and manufacturing methods thereof

Patent metadata

Field	Value
Publication number	US-10608254-B2
Application number	US-201916659373-A
Country	US
Kind code	B2
Filing date	Oct 21, 2019
Priority date	Aug 28, 2015
Publication date	Mar 31, 2020
Grant date	Mar 31, 2020

Abstract

Composites of silicon and various porous scaffold materials, such as carbon material comprising micro-, meso- and/or macropores, and methods for manufacturing the same are provided. The compositions find utility in various applications, including electrical energy storage electrodes and devices comprising the same.

First claim

The invention claimed is:

1. A material comprising a plurality of composite particles, wherein the composite particles comprise:
(a) a porous carbon framework comprising micropores and mesopores, and having:
(i) a total pore volume of greater than 0.6 cm 3 /g;
(ii) a volume fraction of micropores in the range from 20-50% and a volume fraction of mesopores in the range of 50-80%;
(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume; and
(iv) a Dv50 ranging from 5 nm to 20 um;

(b) nano-featured silicon embedded within pores of the porous carbon framework, wherein the weight percent of the nano-featured silicon to the porous carbon framework ranges from 10% to 80%, and
(c) a surface area below 50 m 2 /g.

2. The material of claim 1 , wherein the Dv50 ranges from 2 to 20 microns.

3. The material of claim 1 , wherein the composite particles have a surface area below 20 m 2 /g.

4. The material of claim 1 , wherein the composite particles have a surface area below 30 m 2 /g.

5. The material of claim 1 , wherein the porous carbon framework has a monomodal pore size distribution.

6. The material of claim 1 , wherein the material has a gravimetric capacity between 1200 and 3500 mAh/g when the material is incorporated into an electrode of a lithium based energy storage device.

7. An electrode comprising the material of claim 1 and a binder or a conductive additive, or both.

8. A lithium-based energy storage device comprising the material of claim 1 .

9. A material comprising a plurality of composite particles, wherein the composite particles comprise:
(a) a porous carbon framework comprising micropores and mesopores, and having:
(i) a total pore volume of greater than 0.6 cm 3 /g;
(ii) a volume fraction of micropores in the range from 40-60% and a volume fraction of mesopores in the range of 40-60%;
(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume; and
(iv) a Dv50 ranging from 5 nm to 20 um;

(b) nano-featured silicon embedded within pores of the porous carbon framework, wherein the weight percent of the nano-featured silicon to the porous carbon framework ranges from 10% to 80%, and
(c) a surface area below 50 m 2 /g.

10. The material of claim 9 , wherein the Dv50 ranges from 2 to 20 microns.

11. The material of claim 9 , wherein the composite particles have a surface area below 20 m 2 /g.

12. The material of claim 9 , wherein the composite particles have a surface area below 30 m 2 /g.

13. The material of claim 9 , wherein the porous carbon framework has a monomodal pore size distribution.

14. The material of claim 9 , wherein the material has a gravimetric capacity between 1200 and 3500 mAh/g when the material is incorporated into an electrode of a lithium based energy storage device.

15. An electrode comprising the material of claim 9 and a binder or a conductive additive, or both.

16. A lithium-based energy storage device comprising the material of claim 9 .

17. A material comprising a plurality of composite particles, wherein the composite particles comprise:
(a) a porous carbon framework comprising micropores and mesopores, and having:
(i) a total pore volume of greater than 0.6 cm 3 /g;
(ii) a volume fraction of micropores in the range from 80-95% and a volume fraction of mesopores in the range of 0-10%;
(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume; and
(iv) a Dv50 ranging from 5 nm to 20 um;

(b) nano-featured silicon embedded within pores of the porous carbon framework, wherein the weight percent of the nano-featured silicon to the porous carbon framework ranges from 10% to 80%, and
(c) a surface area below 50 m 2 /g.

18. The material of claim 17 , wherein the Dv50 ranges from 2 to 20 microns.

19. The material of claim 17 , wherein the composite particles have a surface area below 30 m 2 /g.

20. The material of claim 17 , wherein the porous carbon framework has a monomodal pore size distribution.

21. The material of claim 17 , wherein the material has a gravimetric capacity between 1200 and 3500 mAh/g when the material is incorporated into an electrode of a lithium based energy storage device.

22. An electrode comprising the material of claim 17 and a binder or a conductive additive, or both.

23. A lithium-based energy storage device comprising the material of claim 17 .

24. A material comprising a plurality of composite particles, wherein the composite particles comprise:
(a) a porous carbon framework having:
(i) a total pore volume of greater than 0.6 cm 3 /g;
(ii) a volume fraction of micropores greater than 50%;
(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume; and
(iv) a Dv50 ranging from 5 nm to 20 um;

(b) nano-featured silicon embedded within pores of the porous carbon framework, wherein the weight percent of the nano-featured silicon to the porous carbon framework ranges from 10% to 80%, and
(c) a surface area below 50 m 2 /g.

25. The material of claim 24 , wherein the Dv50 ranges from 2 to 20 microns.

26. The material of claim 24 , wherein the composite particles have a surface area below 30 m 2 /g.

27. The material of claim 24 , wherein the porous carbon framework has a monomodal pore size distribution.

28. The material of claim 24 , wherein the material has a gravimetric capacity between 1200 and 3500 mAh/g when the material is incorporated into an electrode of a lithium based energy storage device.

29. An electrode comprising the material of claim 24 and a binder or a conductive additive, or both.

30. A lithium-based energy storage device comprising the material of claim 24 .

Assignees

• Group14 Technologies Inc

Inventors

• Sakshaug Avery J
• Costantino Henry R
• Feaver Aaron M
• Thompkins Leah A
• Geramita Katharine
• Kron Benjamin E
• Fredrick Sarah
• Afkhami Farshid
• Strong Adam

Classifications

• H01M4/625

  Carbon or graphite · CPC title

• C04B38/0064

  Multimodal pore size distribution · CPC title

• H01M4/587 Primary

  for inserting or intercalating light metals · CPC title

• C04B2235/6581

  Total pressure below 1 atmosphere, e.g. vacuum · CPC title

• C04B38/0051

  characterised by the pore size, pore shape or kind of porosity · CPC title