Materials with extremely durable intercalation of lithium and manufacturing methods thereof

Patent metadata

Field	Value
Publication number	US-10756347-B2
Application number	US-201816154572-A
Country	US
Kind code	B2
Filing date	Oct 8, 2018
Priority date	Aug 28, 2015
Publication date	Aug 25, 2020
Grant date	Aug 25, 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 composite comprising a porous carbon scaffold and silicon, wherein the composite comprises from 15 to 85% silicon by weight and a nitrogen-inaccessible volume ranging from 0.05 to 0.5 cm 3 /g, and wherein the composite comprises a plurality of particles having a particle skeletal density ranging from 1.5 to 2.2 g/cm 3 , as measured by helium pycnometry, and wherein the plurality of particles have:
i) a Dv50 from 5 nm to 20 μm;
ii) a span (Dv50)/(Dv90−Dv10) from 100 to less than 1;
iii) a Dv10 of no less than 5 nm, a Dv50 between 500 nm and 5 μm, and a Dv90 no greater than 50 μm; or
iv) a Dv10 of no less than 100 nm, a Dv50 between 2 μm and 8 μm, and a Dv90 no greater than 20 μm.

2. The composite of claim 1 , wherein the plurality of particles have a Dv50 from 5 nm to 20 μm.

3. The composite of claim 1 , wherein the plurality of particles have a span (Dv50)/(Dv90−Dv10) from 100 to less than 1.

4. The composite of claim 1 , wherein the plurality of particles have a span (Dv50)/(Dv90−Dv10) from 100 to 10.

5. The composite of claim 1 , wherein the plurality of particles have a span (Dv50)/(Dv90−Dv10) from 10 to 5.

6. The composite of claim 1 , wherein the plurality of particles have a span (Dv50)/(Dv90−Dv10) from 5 to 2.

7. The composite of claim 1 , wherein the plurality of particles have a span (Dv50)/(Dv90−Dv10) from 2 to 1.

8. The composite of claim 1 , wherein the plurality of particles have a span (Dv50)/(Dv90−Dv10) less than 1.

9. The composite of claim 1 , wherein the plurality of particles have a Dv10 of no less than 5 nm, a Dv50 between 500 nm and 5 μm, and a Dv90 no greater than 50 μm.

10. The composite of claim 1 , wherein the plurality of particles have a Dv10 of no less than 100 nm, a Dv50 between 2 μm and 8 μm, and a Dv90 no greater than 20 μm.

11. The composite of claim 1 , wherein the silicon is amorphous and does not form Li 15 Si 4 when the composite is cycled in a lithium ion half cell between 0.005 and 0.8 V.

12. An electrode comprising a composite according to claim 1 .

13. An energy storage device comprising a composite according to claim 1 .

14. A composite comprising a porous carbon scaffold and silicon, wherein the composite comprises from 15 to 85% silicon by weight and a nitrogen-inaccessible volume ranging from 0.05 to 0.5 cm 3 /g, and wherein the composite comprises a plurality of particles having a particle skeletal density ranging from 1.5 to 2.2 g/cm 3 , as measured by helium pycnometry, wherein the silicon has an oxygen content between 1 and 20%.

15. The composite of claim 14 , wherein the silicon has an oxygen content between 1 and 10%.

16. The composite of claim 14 , wherein the silicon is amorphous and does not form Li 15 Si 4 when the composite cycled in a lithium ion half cell between 0.005 and 0.8 V.

17. An electrode comprising a composite according to claim 14 .

18. An energy storage device comprising a composite according to claim 14 .

19. A composite comprising a porous carbon scaffold and silicon, wherein the composite comprises from 15 to 85% silicon by weight and a nitrogen-inaccessible volume ranging from 0.05 to 0.5 cm 3 /g, and wherein the composite comprises a plurality of particles having a particle skeletal density ranging from 1.5 to 2.2 g/cm 3 , as measured by helium pycnometry, and wherein the composite has a surface area below 200 m 2 /g.

20. The composite of claim 19 , wherein the surface area is below 100 m 2 /g.

21. The composite of claim 19 , wherein the surface area is below 50 m 2 /g.

22. The composite of claim 19 , wherein the surface area is below 30 m 2 /g.

23. The composite of claim 19 , wherein the surface area is below 20 m 2 /g.

24. The composite of claim 19 , wherein the surface area is below 10 m 2 /g.

25. The composite of claim 19 , wherein the surface area is below 5 m 2 /g.

26. The composite of claim 19 , wherein the surface area is below 2 m 2 /g.

27. The composite of claim 19 , wherein the surface area is below 1 m 2 /g.

28. The composite of claim 19 , wherein the silicon is amorphous and does not form Li 15 Si 4 when the composite is cycled in a lithium ion half cell between 0.005 and 0.8 V.

29. An electrode comprising a composite according to claim 19 .

30. An energy storage device comprising a composite according to claim 19 .

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

• H01M4/364 Primary

  as mixtures · CPC title

• H01M4/386

  Silicon or alloys based on silicon · CPC title

• H01M4/625

  Carbon or graphite · CPC title

• H01M4/587 Primary

  for inserting or intercalating light metals · CPC title

• H01M4/0471

  involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis · CPC title