Porous silicon compositions and devices and methods thereof

Patent metadata

Field	Value
Publication number	US-2020220170-A1
Application number	US-202016818384-A
Country	US
Kind code	A1
Filing date	Mar 13, 2020
Priority date	Nov 25, 2015
Publication date	Jul 9, 2020
Grant date	—

Abstract

A porous silicon composition, a porous alloy composition, or a porous silicon containing cermet composition, as defined herein. A method of making: the porous silicon composition; the porous alloy composition, or the porous silicon containing cermet composition, as defined herein. Also disclosed is an electrode, and an energy storage device incorporating the electrode and at least one of the disclosed compositions, as defined herein.

First claim

1 . A porous silicon composition comprising:
a crystalline phase in from 50 to 99 atom % Si by NMR, comprised of crystalline Si in from 95 to 100 wt % by XRD, crystalline forsterite in from 0.1 to 5 wt % by XRD, and crystalline quartz in from 0.1 to 1 wt % by XRD; an amorphous phase comprised of at least one of amorphous silica, amorphous silicate, or a mixture thereof, in from 1 to 50 atom % Si by NMR, based on the total amount of Si; a total Si content in from 20 to 99 wt % by ICP; a total elemental oxygen content of from 0.001 to 1 wt % by difference, based on a 100 wt % total; and a form factor comprising a porous particle.

2 . The porous silicon composition of claim 1 wherein the porous particle comprises:
a continuous phase comprising the porous crystalline silicon composition, and the porous particle having at least one of:
a porous particulate powder form having a d 50 particle size of from 3 to 14 microns;
a percent porosity of from 60 to 80%;
an open pore structure having a pore size diameter from 1 to 1,000 nm, where the total pore volume is greater than 70% for pore diameters greater than 10 nm, and the total pore volume is greater than 40% for pore diameters greater than 40 nm to 1000 nm;
a BET surface area of from 20 to 75 m 2 /g; or a combination thereof.

3 . The porous silicon composition of claim 1 wherein the composition has a 29 Si MAS NMR spectra having a major single peak at a chemical shift of −81 ppm and a diffuse minor signal region at from −95 to −120 ppm.

4 - 7 . (canceled)

8 . An alloy stable porous silicon composition comprising:
a crystalline phase in from 70 to 90 atom % Si by NMR, comprised of crystalline Si in from 20 to 80 wt % by XRD, crystalline forsterite in from 0.1 to 5 wt % by XRD, crystalline quartz in from 0.1 to 1 wt % by XRD, and at least one crystalline metal silicide in from 1 to 80 wt % by XRD; an amorphous phase in from 10 to 30 atom % Si by NMR comprised of at least one of amorphous silica, amorphous silicate, or a mixture thereof; a total Si content in from 20 to 99 wt % by ICP; a total elemental oxygen content of from 0.001 to 1 wt % by difference, based on a 100 wt % total; and a form factor comprising a porous particle.

9 . The composition of claim 8 wherein the particle comprises:
a continuous phase comprising a porous silicon composition; and
a discontinuous phase comprising a metal silicide dispersed in the continuous phase, and the porous particle having at least one of:
a percent porosity (%P) in from 60 to 80 vol%; or
a BET surface area of from 20 to 75 m 2 /g, the porous alloy has an open pore structure having a pore size diameter from 1 to 1,000 nm, where the total pore volume is greater than 85% for pore diameters greater than 10 nm, and the total pore volume is greater than 50% for pore diameters greater than 40 nm to 1000 nm.

10 . The composition of claim 8 wherein the composition has a 29 Si MAS NMR spectra having a major single peak at a chemical shift of −81 ppm, a first diffuse minor signal region from at from −95 to −135 ppm or at from −95 to −120 ppm, and a second diffuse minor signal region at a -50 to -70 ppm.

11 - 15 . (canceled)

16 . A porous silicon containing cermet composition comprising:
a crystalline phase in from 70 to 90 atom % Si by NMR comprised of crystalline Si in from 90 to 95 wt % by XRD, crystalline forsterite in from 0.1 to 5 wt % by XRD, crystalline quartz in from 0.1 to 1 wt % by XRD, and at least one crystalline ceramic component in from to 1 to 10 wt % by XRD; an amorphous phase in from 10 to 30 atom % Si by NMR comprised of at least one of amorphous silica, amorphous silicate, or a mixture thereof. a total Si content in from 20 to 99 wt % by ICP; a total elemental oxygen content of from 0.001 to 1 wt % by difference, based on a 100 wt % total; and a form factor comprising a porous particle.

17 . The composition of claim 16 wherein the porous particle comprises:
a continuous phase comprising: a crystalline silicon; and
a discontinuous phase comprising a ceramic dispersed in the continuous phase, the porous particle having at least one of:
a percent porosity in from 60 to 80%;
an open pore structure having a pore size diameter from 1 to 1,000 nm, where the total pore volume is greater than 85% for pore diameters greater than 10 nm, and the total pore volume is greater than 50% for pore diameters greater than 40 nm to 1000 nm;
a BET surface area of from 20 to 75 m 2 /g, or a combination thereof.

18 . The composition of claim 16 wherein the composition has a 29 Si MAS NMR spectra having a major single peak at a chemical shift of -81 ppm, a first diffuse minor signal region from at from −95 to −130 ppm, and a second diffuse minor signal region at a −35 to −55 ppm.

19 - 26 . (canceled)

Assignees

• Corning Inc

Inventors

• Dutta Indrajit
• Kent Brian Alan
• Tepesch Patrick David
• O'Malley Shawn Michael
• Youngman Randall Eugene

Classifications

• H01M4/386 Primary

  Silicon or alloys based on silicon · CPC title

• H01G11/30

  characterised by their material · CPC title

• C01P2004/61

  Micrometer sized, i.e. from 1-100 micrometer · CPC title

• C01P2006/14

  Pore volume · CPC title

• H01M10/446

  Initial charging measures · CPC title