Composite carbon materials comprising lithium alloying electrochemical modifiers

• US 10,454,103 B2
• Filed: 08/11/2017
• Issued: 10/22/2019
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Group14 Technologies Inc.
• Original Assignee: Group14 Technologies Inc.
• Inventors: Sakshaug, Avery J., Thompkins, Leah A., Costantino, Henry R., Feaver, Aaron M.
• Primary Examiner(s): Gilliam, Barbara L
• Assistant Examiner(s): Zemui, Nathanael T
• Application Number:
  US15/675,462
• Publication Number:
  US 20170346084A1
• Time in Patent Office: 802 Days
• Field of Search: None
• CPC Class Codes: H01G 11/06 with one of the electrodes allowing ions to be reversibly doped thereinto, e.g. lithium ion capacitors [LIC]
• CPC Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01G 11/50 specially adapted for lithium-ion capacitors, e.g. for lithium-doping or for intercalation
• 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 4/0471 involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
• 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 4/1393 of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• 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 4/364 as mixtures
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/386 Silicon or alloys based on silicon
• CPC Class Codes: H01M 4/387 Tin or alloys based on tin
• CPC Class Codes: H01M 4/483 for non-aqueous cells H01M4/485 takes precedence
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

The present application is generally directed to composites comprising a hard carbon material and an electrochemical modifier. The composite materials find utility in any number of electrical devices, for example, in lithium ion batteries. Methods for making the disclosed composite materials are also disclosed.

Claims

1. A method for preparing a silicon-carbon composite, the method comprising contacting an amorphous activated porous carbon material having a total pore volume ranging from 0.6 cc/g to 1.0 cc/g with a gas comprising silane at a temperature of 450°

C., thereby depositing elemental silicon in a pore of the porous carbon material to form the silicon-carbon composite.

2. The method of claim 1, wherein the gas comprising silane further comprises nitrogen.

3. The method of claim 1, wherein the amorphous activated porous carbon material is contacted with the gas comprising silane for a period of time ranging from 5 minutes to 5 hours.

4. The method of claim 1, wherein the amorphous activated porous carbon material is contacted with the gas comprising silane in a kiln or fluidized bed.

5. The method of claim 4, wherein the kiln is a rotary kiln.

6. The method of claim 1, wherein the amorphous activated porous carbon material is contacted with the gas comprising silane at a pressure below atmospheric pressure.

7. The method of claim 1, wherein the amorphous activated porous carbon material has a fractional pore surface area of pores at or below 100 nm that comprises at least 50% of the total pore surface area.

8. The method of claim 1, wherein the amorphous activated porous carbon material has a fractional pore surface area of pores at or below 100 nm that comprises at least 90% of the total pore surface area.

9. The method of claim 1, wherein the amorphous activated porous carbon material comprises particles having a median particle diameter ranging from 1 micron to 10 microns.

10. A method for preparing a silicon-carbon composite, the method comprising contacting an amorphous activated porous carbon material having a total pore volume ranging from 0.6 cc/g to 1.0 cc/g with a gas comprising silane at a temperature between 450°

C. and 500°

C., thereby depositing elemental silicon in a pore of the porous carbon material to form the silicon-carbon composite.

11. The method of claim 10, wherein the gas comprising silane further comprises nitrogen.

12. The method of claim 10, wherein the amorphous activated porous carbon material is contacted with the gas comprising silane for a period of time ranging from 5 minutes to 5 hours.

13. The method of claim 10, wherein the amorphous activated porous carbon material is contacted with the gas comprising silane in a kiln or fluidized bed.

14. The method of claim 13, wherein the kiln is a rotary kiln.

15. The method of claim 10, wherein the amorphous activated porous carbon material is contacted with the gas comprising silane at a pressure below atmospheric pressure.

16. The method of claim 10, wherein the amorphous activated porous carbon material has a fractional pore surface area of pores at or below 100 nm that comprises at least 50% of the total pore surface area.

17. The method of claim 10, wherein the amorphous activated porous carbon material has a fractional pore surface area of pores at or below 100 nm that comprises at least 90% of the total pore surface area.

18. The method of claim 10, wherein the amorphous activated porous carbon material comprises particles having a median particle diameter ranging from 1 micron to 10 microns.