COMPOSITE MATERIALS FOR BATTERY APPLICATIONS

• US 20120282527A1
• Filed: 05/04/2011
• Published: 11/08/2012
• Est. Priority Date: 05/04/2011
• Status: Active Grant

• Current Assignee: UChicago Argonne LLC
• Original Assignee: UChicago Argonne LLC
• Inventors: Amine, Khalil, Yang, Junbing, Abouimrane, Ali, Ren, Jianguo
• Granted Patent: US 9,593,413 B2
• Time in Patent Office: Days
• US Class Current: 429/231.8
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C01B 32/192 starting from graphitic oxides
• CPC Class Codes: C01B 32/22 Intercalation
• CPC Class Codes: C23C 16/045 Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
• CPC Class Codes: C23C 16/06 characterised by the deposition of metallic material
• CPC Class Codes: C23C 16/24 Deposition of silicon only
• CPC Class Codes: C23C 16/40 Oxides
• CPC Class Codes: C23C 16/403 of aluminium, magnesium or beryllium
• CPC Class Codes: C23C 16/442 using fluidised bed process
• 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 4/587 for inserting or intercalating light metals
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A process for producing nanocomposite materials for use in batteries includes electroactive materials are incorporated within a nanosheet host material. The process may include treatment at high temperatures and doping to obtain desirable properties.

Claims

1. A process comprising:

contacting a gaseous electroactive material precursor with a carbonaceous, exfoliated nanosheet material to form a nanocomposite material;

wherein;

the carbonaceous, exfoliated nanosheet material comprises a plurality of layers; and

the nanocomposite material comprises;

an electroactive material intercalated between individual layers of the plurality of layers,

an electroactive material deposited on one or more surfaces of the individual layers of the plurality of layers;

or

an electroactive material both intercalated between individual layers of the plurality of layers and deposited on one or more surfaces of the individual layers of the plurality of layers.

2. The process of claim 1, wherein the carbonaceous, exfoliated nanosheet material comprises graphene.

3. The process of claim 1, wherein the electroactive material comprises Si, Sn, Pb, Al, Au, Pt, Zn, Cd, Ag, Mg, or Mo.

4. The process of claim 1, wherein the electroactive material comprises an oxide of Si, Sn, Pb, Al, Au, Pt, Zn, Cd, Ag, Mg or Mo.

5. The process of claim 1, wherein the electroactive material comprises Si or Sn.

6. The process of claim 1, wherein the electroactive material is not the same as the layered nanosheet material.

7. The process of claim 1, wherein the contacting comprises depositing the gaseous electroactive material precursor via chemical vapor deposition.

8. The process of claim 1, wherein the contacting comprises depositing the gaseous electroactive material precursor via a fluidized bed chemical vapor deposition process.

9. The process of claim 1, wherein the gaseous electroactive material precursor comprises one or more silicon-containing compounds.

10. The process of claim 1, wherein the gaseous electroactive material precursor comprises includes silicon-containing compound which is selected from the group consisting of silane, silicon tetrachloride, trichlorosilane, trichloromethylsilane, dichlorosilane, dichloromethylsilane, dichlorodimethylsilane, chlorotrimethylsilane, chlorosilane, chloromethylsilane, chlorodimethylsilane, phenylsilane, tetramethoxysilane, tetraethoxysilane, cyclopropylsilane, cyclobutylsilane, cyclopentylsilane, cyclohexylsilane, cyclooctylsilane, diphenylsilane, dicyclohexylsilane, n-butylmethylsilane, tert-butylmethylsilane, or tert-butylphenylsilane.

11. The process of claim 1, wherein the electroactive material precursor includes a tin-containing compound.

12. The process of claim 11, wherein the tin-containing compound is monobutyltin trichloride, methyltin trichloride isobutyltin trichloride, butyl dichlorotin acetate, butyldichlorotin dicetate, diisobutyltin dichloride, methyltin trichloride, dimethyltin dichloride, dibutyltin dichloride di-t-butyltin dichloride or tin tetrachoride.

13. The process of claim 1, wherein the electroactive material is substantially homogenously intercalated within the plurality of layers.

14. The process of claim 1, wherein the plurality of layers comprises at least two individual layers which each have a thickness of about 0.335 nm.

15. The process of claim 1, wherein the electroactive material comprises a film.

16. The process of claim 1, wherein the electroactive material comprises particles.

17. The process of claim 1, wherein the carbonaceous, exfoliated nanosheet material comprises a dopant comprising N, S, or O.

18. The process of claim 1, further comprising heating the nanocomposite material to a temperature between 500°

C. to 1500°

C.

19. The process of claim 18, wherein the heating comprises heating the nanocomposites material in the presence of a reactive gas comprising hydrogen, ammonia, a phosphorus containing gas, or a boron-containing gas.

20. A material prepared by the process of claim 1.

21. An electrochemical device comprising the material of claim 20.