Multiphase nanocomposite material and method for its manufacture

• US 7,169,328 B2
• Filed: 01/16/2004
• Issued: 01/30/2007
• Est. Priority Date: 01/17/2003
• Status: Expired due to Term

• Current Assignee: A123 Systems Incorporated
• Original Assignee: T&N Technology Limited (Apollo Global Management, Inc.)
• Inventors: Wang, Liya, Miller, John
• Primary Examiner(s): Kopec; Mark
• Assistant Examiner(s): VIJAYAKUMAR, KALLAMBELLA M
• Application Number:
  US10/759,348
• Publication Number:
  US 20040146734A1
• Time in Patent Office: 1,110 Days
• Field of Search: 252/518.1, 252/519, 252/500, 429/218.1, 429/209, 429/231.95, 429/219, 429/225, 429/226, 429/231.6, 420/557, 420/576, 420/129, 420/590, 264/69, 264/328.6, 428/547, 428/614
• US Class Current: 252/500
• CPC Class Codes: B22F 1/07 Metallic powder characterised by particles having a nanoscale microstructure nanosized particles B22F1/054
• CPC Class Codes: B22F 1/08 Metallic powder characterised by particles having an amorphous microstructure
• CPC Class Codes: B22F 1/09 Mixtures of metallic powders
• CPC Class Codes: B22F 1/12 Metallic powder containing non-metallic particles containing lubricating or binding agents or organic material B22F1/10
• CPC Class Codes: B22F 2009/041 by mechanical alloying, e.g. blending, milling
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 9/005 Transformation into amorphous state by milling
• CPC Class Codes: B22F 9/04 starting from solid material, e.g. by crushing, grinding or milling C22C1/1084 takes precedence; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 428/12021 having composition or density gradient or differential porosity

Abstract

A multiphase composite material having utility as an electrochemical electrode or catalyst includes a first active phase which is an amorphous, electrochemically active material; and a second, stabilizer phase which includes one or more of: metals, carbon, ceramics, and intermetallic compounds. The stabilizer phase is configured as a plurality of spaced apart regions having the active phase disposed therebetween. The active phase may comprise one or more of: Sn, Sb, Bi, Pb, Ag, In, Si, Ge, and Al. The stabilizer phase may include one or more of: Fe, Zr, Ti, and C. Also disclosed are electrodes and batteries which include the material as well as methods for manufacturing the material by using a mechanical alloying process.

Claims

1. An electrode comprising:

a multiphase composite material, said multiphase composite material comprising;

a first, active, phase comprising an amorphous, electrochemically active material including nanophase domains of a material selected from the group consisting of;

Sn, Sb, Bi, Pb, Ag, In, Si, Ge, Al, and combinations thereof; and

a second, stabilizer, phase comprising a ceramic, said stabilizer phase being configured as a plurality of spaced apart regions having said active phase interspersed therebetween, said stabilizer phase being electrochemically active.

2. The electrode of claim 1, wherein said stabilizer phase includes at least one element selected from the group consisting of:

Fe, Zr, Ti, and C.

3. The electrode of claim 1, wherein said stabilizer phase comprises a member selected from the group consisting of:

metal nitrides, metal carbides, metal oxynitrides, metal oxycarbides, and combinations thereof.

4. The electrode of claim 1, wherein said spaced apart regions of said stabilizer phase have a size in the range of 10–

100 nanometers.

5. A method of making a multiphase composite material, said method comprising the steps of:

providing a plurality of components, said components including the elements of which said multiphase composite material is comprised; and

subjecting said plurality of components to a mechanical alloying process wherein said mechanical alloying process comprises a staged process wherein a first portion of said plurality of components are subjected to a first mechanical alloying process so as to produce a first component of said multiphase composite material, and a second portion of said components are subsequently subjected to a second mechanical alloying process with said component;

whereby said multiphase composite material is formed.

6. A method of making a multiphase composite material, said method comprising the steps of:

providing a plurality of components, said components including the elements of which said multiphase composite material is comprised; and

subjecting said plurality of components to a mechanical alloying process which is a substitutional process wherein, in a first step, a first composition which includes a first and second element of said multiphase composite material is subjected to a mechanical alloying process along with a third composition which is comprised of a third element and a fourth element of said multiphase composite material, wherein said third element displaces said second element from said first composition so as to form a second composition which includes said first and third element.

7. A multiphase, composite material comprising:

a first, electrochemically active phase including amorphous, nanophase domains of tin or silicon therein; and

a second, stabilizer phase comprising an electrochemically active material selected from the group consisting of metal nitrides, metal carbides, metal oxynitrides, metal oxycarbides, and combinations thereof, said stabilizer phase comprising a matrix configured as a plurality of spaced apart regions having said first phase interspersed therebetween.

8. The material of claim 7, wherein said active phase comprises, on a weight basis, 30–

60% of said material.

9. The material of claim 7, wherein said nanophase domains have a size in the range of 10–

30 nanometers.

10. The material of claim 7, wherein said stabilizer phase comprises an amorphous material.

11. The material of claim 7, wherein said stabilizer phase comprises a crystalline material.

12. The material of claim 7, wherein said material is prepared by a mechanical alloying process.

13. The material of claim 12, wherein said mechanical alloying process is a ball milling process.

14. The material of claim 12, wherein said mechanical alloying process is an attritor milling process.

15. The material of claim 12, wherein said mechanical alloying process is a grinding process.