Lithium carbon composite battery

Patent metadata

Field	Value
Publication number	US-2025030000-A1
Application number	US-202218711025-A
Country	US
Kind code	A1
Filing date	Nov 17, 2022
Priority date	Nov 17, 2021
Publication date	Jan 23, 2025
Grant date	—

Abstract

Disclosed herein are particulate lithium carbon composite materials and devices containing the same.

First claim

1 . A lithium carbon composite, comprising:
a) a porous carbon scaffold comprising a pore volume; and b) a lithium content of 30% to 70% by weight,
wherein the lithium resides within pores of the porous carbon scaffold.

2 . The lithium carbon composite of claim 1 , wherein a pore volume of the porous carbon scaffold is greater than 0.5 cm 3 /g.

3 . The lithium carbon composite of claim 1 , wherein the pore volume comprises micropores.

4 . The lithium carbon composite of claim 1 , further comprising a plurality of particles having a Dv50 between 0.1 and 50 microns.

5 . The lithium carbon composite of claim 1 , wherein a surface area of the lithium carbon composite is less than 30 m 2 /g.

6 . The lithium carbon composite of claim 1 , further comprising a +1 oxidation state occupying interstitial sites complexed with the carbon and forming different stoichiometries with lithium according to the formula Li x C 6 , wherein x=1 to 2.

7 . The lithium carbon composite of claim 1 , wherein a capacity of the lithium carbon composite is greater than 900 m 2 /g.

8 . The lithium carbon composite of claim 1 , wherein an average Coulombic efficiency of the lithium carbon composite is greater than 0.9970.

9 . The lithium carbon composite of claim 1 , further comprising a terminal particle coating which is a carbon coating.

10 . The lithium carbon composite of claim 1 , further comprising a terminal particle coating which is an ALD coating comprising an oxide comprising aluminum, zirconium, titanium, or combinations thereof.

11 . A plurality of lithium carbon composite particles, comprising:
a) a carbon scaffold comprising:
i) micropores, and
ii) a pore volume of greater than 0.5 cm 3 /g; and
b) lithium residing within 10% to 90% of the carbon scaffold pore volume, wherein: a lithium content of the lithium carbon composite particles is 30% to 70% by weight; a Dv50 of the lithium carbon composite particles is between 0.1 and 50 microns; and a surface area of the lithium carbon composite particles is less than 30 m 2 /g.

12 . A plurality of lithium carbon composite particles, comprising:
a) a carbon scaffold comprising:
i) micropores, and;
ii) a pore volume of greater than 0.5 cm 3 /g;
b) lithium residing within 10% to 90% of the carbon scaffold pore volume; and c) a terminal coating,
wherein:
a lithium content of the lithium carbon composite particles is 30% to 70% by weight;
a Dv50 of the lithium carbon composite particles is between 0.1 and 50 microns; and
a surface area of the lithium carbon composite particles is less than 30 m 2 /g.

13 . An electrode comprising the lithium carbon composite particles of claim 11 .

14 . An electrode comprising the lithium carbon composite particles of claim 12 .

15 . The electrode of claim 13 , further comprising at least one binder material and at least one carbon material.

16 . The electrode of claim 15 , wherein the at least one binder material is selected from a styrene-butadiene rubber sodium carboxymethylcellulose (SBR-Na-CMC), a polyvinylidene difluoride (PVDF), a polyimide (PI), a polyacrylic acid (PAA), and combinations thereof.

17 . The electrode of claim 15 , wherein the at least one carbon material is selected from a graphite, a graphene, a carbon conductive additive, Super P, Ketjenblack carbon, carbon nanotubes, carbon nanostructures, and combinations thereof.

18 . A lithium carbon battery comprising the lithium carbon composite particles of claim 11 .

19 . A method of manufacturing a lithium carbon composite, the method comprising:
a) providing a particulate porous carbon scaffold; b) mixing the particulate porous carbon scaffold with a solid lithium metal in the presence of an inert atmosphere to obtain a mixture; c) heating the mixture at 180° C. to 1300° C. to melt the lithium metal; and d) impregnating the molten lithium metal into pores of the particulate porous carbon scaffold particles.

20 . A method of manufacturing a particulate lithium carbon composite material, the method comprising:
a) mixing polymer precursors and storing for a period of time at sufficient temperature to allow for polymerization of the polymer precursors to obtain a polymer material; b) carbonizing the polymer material to create a porous carbon material comprising a pore volume of greater than 0.5 cm 3 /g; c) comminuting the porous carbon material to create a plurality of porous carbon scaffold particles comprising a Dv50 between 0.1 and 50 microns; d) mixing the porous carbon scaffold particles with solid lithium metal in the presence of an inert atmosphere to obtain a mixture; e) heating the mixture at 180° C. to 1300° C. to melt the lithium metal; and f) impregnating the molten lithium metal into pores of the porous carbon scaffold particles.

21 . A method of manufacturing a lithium carbon composite, the method comprising:
a) providing a particulate porous carbon scaffold; b) mixing the particulate porous carbon scaffold with solid lithium metal in the presence of an inert atmosphere to obtain a mixture; c) heating the mixture at 180° C. to 1300° C. to melt the lithium metal; d) impregnating the molten lithium metal into pores of the particulate porous carbon scaffold; and e) heating the lithium impregnated particles in the presence of acetylene at 350° C. to 1050° C.

22 . A method of manufacturing a particulate lithium carbon composite material, the method comprising:
a) mixing polymer precursors and storing for a period of time at sufficient temperature to allow for polymerization of the precursors to obtain a polymer material; b) carbonizing the polymer material to create a porous carbon material comprising a pore volume of greater than 0.5 cm 3 /g; c) comminuting the porous carbon material to create a plurality of porous carbon scaffold particles comprising a Dv50 between 0.1 and 50 microns; d) mixing the porous carbon scaffold particles with solid lithium metal in the presence of an inert atmosphere to obtain a mixture; e) heating the mixture at 180° C. to 1300° C. to melt the lithium metal; f) impregnating the molten lithium metal into pores of the porous carbon scaffold particles; and g) heating the lithium impregnated particles in the presence of acetylene at 350° C. to 1050° C.

Assignees

• Group14 Technologies Inc

Inventors

• Phillip Nathan D
• Sakshaug Avery J
• Patel Rajankumar
• Dhanabalan Abirami
• Timmons Christopher
• Feaver Aaron M
• Costantino Henry R

Classifications

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M10/052

  Li-accumulators · CPC title

• H01M4/625

  Carbon or graphite · CPC title

• H01M4/622

  being polymers · CPC title

• H01M4/362 Primary

  Composites · CPC title