Anode compositions for rechargeable batteries and methods of making same

• US 10,050,260 B2
• Filed: 05/27/2015
• Issued: 08/14/2018
• Est. Priority Date: 05/29/2014
• Status: Active Grant

• Current Assignee: Johnson Matthey Public Limited Company
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Obrovac, Mark N., Zhao, Xiuyun
• Primary Examiner(s): Kelly, Cynthia H
• Assistant Examiner(s): Wills, Monique M
• Application Number:
  US15/312,202
• Publication Number:
  US 20170098820A1
• Time in Patent Office: 1,175 Days
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 2004/028 Positive electrodes
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/0471 involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
• CPC Class Codes: H01M 4/049 Manufacturing of an active layer by chemical means
• CPC Class Codes: H01M 4/133 Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/1395 of electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/362 Composites
• CPC Class Codes: H01M 4/386 Silicon or alloys based on silicon
• CPC Class Codes: H01M 4/62 Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
• CPC Class Codes: H01M 4/622 being polymers
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An anode composition includes an electrochemically active material comprising silicon; and a cement.

Claims

1. An anode composition comprising:

an electrochemically active material comprising silicon; and

a cement;

wherein the electrochemically active material and the cement form secondary composite particles, the secondary composite particles comprising the electrochemically active material and the cement.

2. The anode composition of claim 1, wherein the cement comprises an acid-base cement.

3. The anode composition according to claim 1, wherein the electrochemically active material comprises an insulating phase.

4. The anode composition according to claim 1, wherein the electrochemically active material comprises a conducting phase.

5. The anode composition according to claim 1, wherein the silicon is present in a form selected from the following:

elemental silicon, a metal silicide, a silicon carbide, a silicon nitride, a silicon boride, a silicon oxide, or combinations thereof.

6. The anode composition according to claim 1, wherein the electrochemically active material comprises elemental silicon.

7. The anode composition according to claim 1, wherein the electrochemically active material has a formula (I):

Si_aSn_bM_cC_dQ_eO_fE_g 

 

(I)

where a, b, c, d, e, f and g represent atomic percent values and (i) a>

0;

(ii) b≥

0, (iii) c≥

0, (iv) d≥

0;

(v) e≥

0;

(vi) f≥

0;

(vii) g≥

0;

(viii) M is one or more metals selected from the group consisting of manganese, molybdenum, niobium, tungsten, tantalum, iron, copper, titanium, vanadium, chromium, nickel, cobalt, zirconium, yttrium, or combinations thereof;

(ix) Q is one or more elements selected from the group consisting of sodium, lithium, potassium, magnesium, calcium, titanium, boron, aluminum, a rare earth metal, or combinations thereof; and

(x) E is one or more elements selected from the group consisting of boron and nitrogen.

8. The anode composition according to claim 1, wherein the electrochemically active material has a formula (II):

Si_xSn_qM_yC_z 

 

(II)

where q, x, y, and z represent atomic percent values and (i) (q+x)>

(2y+z);

(ii) x>

0;

(iii) q≥

0, (iv) z≥

0;

(v) y≥

0; and

(vi) M is one or more metals selected from manganese,

molybdenum, niobium, tungsten, tantalum, iron, copper, titanium, vanadium, chromium, nickel, cobalt, zirconium, yttrium, or combinations thereof.

9. The anode composition according to claim 8, wherein the Si, Sn, M, and C elements are arranged in the form of a multi-phase microstructure comprising:

(i) an amorphous phase comprising silicon;

(ii) a nanocrystalline phase comprising a metal silicide;

(iii) a phase comprising silicon carbide when z>

0; and

(iv) an amorphous phase comprising Sn when q>

0.

10. The anode composition according to claim 2, wherein the composite particles have an average size of between 5-50 μ

m.

11. The anode composition according to claim 2, wherein the composite particles have an average surface area of between 0.1-10 m²/g.

12. The anode composition according to claim 2, wherein the amount of cement in the particles is between 5-40 wt. %, based upon the total weight of the composite particles.

13. A rechargeable battery comprising:

a cathode;

an electrolyte; and

an anode comprising the anode composition according to claim 1.

14. An electronic device comprising a rechargeable battery according to claim 13.

18. A method of making a rechargeable battery, the method comprising:

providing a cathode;

providing an anode, wherein the anode comprises the anode composition according to claim 1; and

incorporating the cathode and anode into a battery comprising an electrolyte.

19. A negative electrode composition comprising:

the anode composition according to claim 1;

graphite; and

a binder.

20. The rechargeable battery of claim 13, wherein the rechargeable battery comprises a lithium-ion battery.

15. A method of making an anode composition, the method comprising:

combining (i) precursor materials of an electrochemically active material comprising silicon; and

(ii) a base source to form a mixture;

milling the mixture to form a milled mixture;

combining the milled mixture and an acid source to form a second mixture; and

subjecting the second mixture to a heat treatment to form an acid-base cement monolith.

16. The method of making an anode composition according to claim 15, wherein the acid source comprises an aqueous solution of a polymeric acid.

17. The method of making an anode composition according to claim 16, wherein the polymeric acid comprises poly(acrylic acid).