High surface area porous carbon materials as electrodes

Patent metadata

Field	Value
Publication number	US-2018287162-A1
Application number	US-201615766261-A
Country	US
Kind code	A1
Filing date	Oct 10, 2016
Priority date	Oct 8, 2015
Publication date	Oct 4, 2018
Grant date	—

Abstract

Embodiments of the present disclosure pertain to an electrode that includes: a porous carbon material; a metal (e.g., Li) associated with the porous carbon material; and a conductive additive (e.g., graphene nanoribbons) associated with the porous carbon material. The metal may be in the form of a non-dendritic or non-mossy coating on a surface of the porous carbon material. The electrodes may also be associated with a substrate, such as a copper foil. The electrodes may be utilized as anodes or cathodes in energy storage devices, such as lithium ion batteries. Additional embodiments pertain to energy storage devices that contain the electrodes of the present disclosure. Further embodiments pertain to methods of making the electrodes by associating porous carbon materials with a conductive additive, a metal, and optionally a substrate. The electrode may then be incorporated as a component of an energy storage device.

First claim

What is claimed is:

1 - 54 . (canceled)

55 . An energy-storage device comprising:
an anode; and a cathode; at least one of the anode and the cathode including an electrode having:
a conductive substrate;
a layer of porous carbon material particles on the conductive substrate, the layer of the porous carbon material particles having a surface of a surface area greater than 2,000 square meters per gram; and
a metal film on the surface.

56 . The energy-storage device of claim 55 , wherein the metal film consists essentially of lithium.

57 . The energy-storage device of claim 56 , wherein the lithium has a lithium mass, the layer of the porous carbon material particles has a carbon mass, and the ratio of the lithium mass to the carbon mass is at least one-to-two.

58 . The energy-storage device of claim 55 , wherein the metal film is uniform.

59 . The energy-storage device of claim 55 , wherein the porous carbon material of the particles is selected from the group consisting of asphalt-based porous carbon materials, asphaltene-based porous carbon materials, anthracite-based porous carbon materials, coal-based porous carbon materials, coke-based porous carbon materials, biochar-based porous carbon materials, carbon black-based porous carbon materials, coal-based porous carbon materials, oil product-based porous carbon materials, bitumen-based porous carbon materials, tar-based porous carbon materials, pitch-based porous carbon materials, polymer-based porous carbon materials, protein-based porous carbon materials, carbohydrate-based porous carbon materials, cotton-based porous carbon materials, fat-based porous carbon materials, waste-based porous carbon materials, graphite-based porous carbon materials, melamine-based porous carbon materials, wood-based porous carbon materials, porous graphene, porous graphene oxide, high surface area active carbons, and combinations thereof.

60 . The energy-storage device of claim 55 , further comprising sulfur diffused within the layer of the porous carbon material particles.

61 . The energy-storage device of claim 55 , further comprising conductive additives between the porous carbon material particles.

62 . The energy-storage device of claim 61 , wherein the conductive additives comprise graphene.

63 . The energy storage device of claim 62 , wherein the conductive additives comprise graphene nanoribbons mixed with the porous carbon material particles.

64 . The energy-storage device of claim 55 , the layer of porous carbon material particles prepared by a process comprising mixing a carbon source with potassium hydroxide to create a carbon mixture.

65 . The energy-storage device of claim 64 , the process further comprising heating the carbon mixture.

66 . The energy-storage device of claim 64 , the process further comprising removing oil from the carbon source before the mixing.

67 . The energy-storage device of claim 55 , wherein the porous carbon material particles comprise a plurality of micropores and mesopores.

68 . A method for making an electrode for an energy-storage device, the method comprising:
mixing carbon with potassium hydroxide to produce a carbon mixture; heating the carbon mixture to activate the carbon; applying the activated carbon to a conductive substrate; and coating the activated carbon with a metal film.

69 . The method of claim 68 , further comprising heating a carbon source comprised of oil to remove the oil from the carbon source and leave the carbon.

70 . The method of claim 68 , wherein the activated carbon has a surface area greater than 2,000 square meters per gram.

71 . The method of claim 70 , wherein the surface area is greater than 4,000 square meters per gram.

72 . The method of claim 68 , further comprising adding a conductive additive to the carbon mixture before applying the activated carbon to the conductive substrate.

73 . The method of claim 72 , wherein the conductive additive includes graphene nanoribbons.

74 . The method of claim 68 , further comprising grinding the carbon before the mixing.

75 . The method of claim 68 , wherein the coating comprises forming a slurry of the activated carbon.

76 . The method of claim 68 , wherein the metal film comprises lithium metal.

77 . The method of claim 68 , further comprising obtaining the carbon from a material selected from the group consisting of asphalt-based porous carbon materials, asphaltene-based porous carbon materials, anthracite-based porous carbon materials, coal-based porous carbon materials, coke-based porous carbon materials, biochar-based porous carbon materials, carbon black-based porous carbon materials, coal-based porous carbon materials, oil product-based porous carbon materials, bitumen-based porous carbon materials, tar-based porous carbon materials, pitch-based porous carbon materials, polymer-based porous carbon materials, protein-based porous carbon materials, carbohydrate-based porous carbon materials, cotton-based porous carbon materials, fat-based porous carbon materials, waste-based porous carbon materials, graphite-based porous carbon materials, melamine-based porous carbon materials, wood-based porous carbon materials, porous graphene, porous graphene oxide, high surface area active carbons, and combinations thereof.

Assignees

• Tour James M
• Tuo Wang
• Salvatierra Rodrigo Villegas
• Jalilov Almaz S
• Univ Rice William M

Inventors

• Tour James M
• Tuo Wang
• Salvatierra Rodrigo Villegas
• Jalilov Almaz S

Classifications

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M4/1395

  of electrodes based on metals, Si or alloys · CPC title

• H01M4/0414

  by screen printing · CPC title

• H01M4/0404 Primary

  by coating on electrode collectors · CPC title

• H01M4/662

  Alloys (collectors of lead alloys H01M4/685) · CPC title