Preparation of polymeric resins and carbon materials

Patent metadata

Field	Value
Publication number	US-12006400-B2
Application number	US-202318302597-A
Country	US
Kind code	B2
Filing date	Apr 18, 2023
Priority date	Feb 9, 2012
Publication date	Jun 11, 2024
Grant date	Jun 11, 2024

Abstract

The present application is directed to methods for preparation of carbon materials. The carbon materials comprise enhanced electrochemical properties and find utility in any number of electrical devices, for example, as electrode material in ultracapacitors or batteries.

First claim

The invention claimed is:

1. A battery electrode composition comprising a plurality of composite particles having an average particle size, Dv,50, of less than 1 mm and wherein individual composite particles comprise:
a. carbon material comprising:
i. a pore structure having micropores and mesopores,
ii. a maximum theoretical capacitance greater than 20 F/cm3 as measured at a current density of 0.5 Amp/g employing an electrolyte comprising tetraethylammonium tetrafluoroborane in acetonitrile,
iii. a specific surface area of at least 500 m2/g, and
iv. less than 500 ppm of all atoms having a molecular weight between 11 and 92, as measured by photon induced x-ray emissions; and

b. an electrochemical modifier incorporated within the pore structure of the carbon material, wherein the electrochemical modifier comprises elemental silicon.

2. The carbon material of claim 1 , wherein the specific surface area is between 1000 m2/g and 1500 m2/g.

3. The carbon material of claim 1 , wherein the maximum theoretical capacitance is greater than 23 F/cm3.

4. The battery electrode composition of claim 1 , wherein the electrochemical modifier comprises an elemental silicon content of at least 25% to 95% weight percent.

5. A battery electrode composition comprising a plurality of composite particles having an average particle size, Dv,50, of less than 1 mm and wherein individual composite particles comprise:
a. carbon material comprising:
i. a pore structure having micropores and mesopores,
ii. a maximum theoretical capacitance greater than 20 F/cm3 as measured at a current density of 0.5 Amp/g employing an electrolyte comprising tetraethylammonium tetrafluoroborane in acetonitrile,
iii. a pore volume of at least 0.5 cm 3 /g, and
iv. less than 500 ppm of all atoms having a molecular weight between 11 and 92, as measured by photon induced x-ray emissions; and

b. an electrochemical modifier incorporated within the pore structure of the carbon material, wherein the electrochemical modifier comprises elemental silicon.

6. The battery electrode composition of claim 5 , wherein the maximum theoretical capacitance of the carbon material is greater than 23 F/cm3.

7. The battery electrode composition of claim 5 , wherein the carbon material is electrically conductive.

8. The battery electrode composition of claim 5 , wherein the electrochemical modifier comprises an elemental silicon content of at least 25% to 95% weight percent.

9. The battery electrode composition of claim 5 , wherein the carbon material is spherical.

10. A battery electrode composition comprising a plurality of composite particles having an average particle size, Dv,50, of less than 1 mm and wherein individual composite particles comprise:
a. a carbon material comprising:
i. a pore volume totaling at least 0.5 cc/g, wherein the total pore volume comprises micropores and mesopores,
ii. a GM greater than or equal to 21, and
iii. less than 500 ppm of all atoms having a molecular weight between 11 and 92, as measured by photon induced x-ray emissions; and

b. an electrochemical modifier disposed within the pore volume of the carbon material, wherein the electrochemical modifier comprises elemental silicon,
wherein GM is measured as a ratio of a BET specific surface area of the carbon material and the pore volume of the carbon material multiplied by 100, such that the GM is calculated according to the equation below wherein the BET specific surface area is in units m 2 /g and the pore volume is in units cm 3 /g:

G
⁢
M

=

[

BET
⁢

Specific
⁢

Surface
⁢

Area
(

m
2

g

)

]

[

100
×
Pore
⁢

Volume
(

cm
3

g

)

]

.

11. The composite particle of claim 10 , wherein the carbon material has a tap density of at least 0.5 g/cc.

12. The composite material of claim 10 , wherein the carbon material has a span of 3 or less, wherein the span is defined as (Dv90−Dv10)/Dv50, and wherein Dv10, Dv50, and Dv90 refer to the pore size at 10%, 50%, and 90% of the distribution.

13. The carbon material of claim 10 , wherein the carbon material comprises less than 3 ppm of sulfur.

14. The composite material of claim 10 , wherein the carbon material comprises a pore volume totaling at least 0.7 cm3/g.

15. The composite material of claim 10 , wherein the carbon material further comprises a specific surface area of at least 500 m2/g.

16. The composite material of claim 10 , wherein the pore volume further comprise at least 0.1 cc/g of pores less than 20 angstroms.

17. The composite material of claim 10 , wherein the carbon material has a peak pore volume between 2 nm and 10 nm.

18. The carbon composite of claim 10 , wherein greater than 90% of the carbon material is substantially spherical.

19. The carbon composite of claim 10 , wherein greater than 95% of the carbon material is substantially spherical.

20. The composite particle of claim 10 , wherein the electrochemical modifier comprises an elemental silicon content of at least 25% to 95% weight percent.

21. A battery comprising the composite particle of claim 10 .

Assignees

• Group14 Technologies Inc

Inventors

• Geramita Katharine
• Kron Benjamin E
• Costantino Henry R
• Feaver Aaron M
• Sakshaug Avery J
• Thompkins Leah A
• Chang Alan Tzu-Yang

Classifications

• C01B32/312

  Preparation · CPC title

• H01M12/08

  composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type · CPC title

• H01M10/054

  Accumulators with insertion or intercalation of metals other than lithium, e.g. with magnesium or aluminium · CPC title

• H01M4/96

  Carbon-based electrodes · CPC title

• H01M4/36

  Selection of substances as active materials, active masses, active liquids · CPC title