High performance anode material for lithium-ion battery

• US 7,722,991 B2
• Filed: 08/09/2006
• Issued: 05/25/2010
• Est. Priority Date: 08/09/2006
• Status: Active Grant

• Current Assignee: Toyota Motor Corporation
• Original Assignee: T&N Technology Limited, Toyota Motor Corporation, Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Miller, John, Yokoishi, Shoji, Silkowski, Chris, Li, Wen, Wang, Liya, Zhang, Pu, Mani, Suresh, Ma, Junqing, Yin, Shih-Chieh, Stamm, Kimber L., Richard, Monique, Glomski, Brian
• Primary Examiner(s): Ryan; Patrick
• Assistant Examiner(s): WILLS, MONIQUE M
• Application Number:
  US11/463,394
• Publication Number:
  US 20080038638A1
• Time in Patent Office: 1,385 Days
• Field of Search: 429/231.95, 429/209, 429/214, 429/232, 429/217, 429/218.1, 429/213, 252/182.1
• US Class Current: 429/231.95
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/38 of elements or alloys
• 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 4/62 Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
• CPC Class Codes: H01M 4/621 Binders
• CPC Class Codes: H01M 4/624 Electric conductive fillers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An anode material with lithium-alloying particles contained within a porous support matrix is provided. The porous support matrix preferably has a porosity of between 5 and 80% afforded by porosity channels and expansion accommodation pores, and is electrically conductive. More preferably the support matrix has a porosity of between 10 and 50%. The support matrix is made from an organic polymer, an inorganic ceramic or a hybrid mixture of organic polymer and inorganic ceramic. The organic polymer support matrix and can be made from a rod-coil polymer, a hyperbranched polymer, UV cross-linked polymer, heat cross-linked polymer or combination thereof. An inorganic ceramic support matrix can be made from at least one group IV-VI transition metal compound, with the compound being a nitride, carbide, oxide or combination thereof. The lithium-alloying particles are preferably nanoparticles with a mean linear dimension of between 5 and 500 nanometers, and more preferably have a mean linear dimension of between 5 and 50 nanometers.

Claims

1. A battery comprising:

a cathode;

a separator;

an anode having a composite particle, said composite particle having a matrix defining a void volume, said void volume comprised of a plurality of porosity channels and an expansion accommodation pore; and

a lithium-alloying particle, said lithium-alloying particle contained within said expansion accommodation pore of said anode.

2. The invention of claim 1 wherein said lithium-alloying particle is an unlithiated particle.

3. The invention of claim 1 wherein said lithium-alloying particle is a lithiated particle.

4. The invention of claim 1 wherein said matrix contains a conductivity enhancer.

5. The invention of claim 4 wherein said conductivity enhancer is an electroactive material.

6. The invention of claim 4 wherein said conductivity enhancer is an ionic conductive material.

7. The invention of claim 1 wherein said matrix contains a binding element.

8. The invention of claim 1 wherein said matrix contains an adhesion promoter.

9. The invention of claim 1 wherein said matrix is an organic polymer.

10. The invention of claim 9 wherein said polymer is selected from the group consisting of:

a rod-coil polymer, a hyperbranched polymer, UV cross-linked polymer, heat cross-linked polymer, and a combination thereof.

11. The invention of claim 1 wherein said matrix is an inorganic ceramic.

12. The invention of claim 11 wherein said ceramic is a group IV-VI transition metal compound, said compound being selected from the group consisting of:

nitrides, carbides, oxides, and combinations thereof.

13. The invention of claim 1 wherein said matrix is a hybrid matrix, said hybrid matrix being a mixture of an organic polymer and an inorganic ceramic.

14. The invention of claim 1 wherein said lithium-alloying particle has a composition selected from the group consisting of:

tin, silicon, germanium, lead, antimony, aluminum, tin alloys and silicon alloys.

15. The invention of claim 1 wherein said lithium-alloying particle is a nanoparticle having a mean linear dimension of between 1 and 999 nanometers.

16. The invention of claim 1 wherein said lithium-alloying particle is a nanoparticle having a mean linear dimension of between 5 and 500 nanometers.

17. The invention of claim 1 wherein said lithium-alloying particle is a nanoparticle having a mean linear dimension of between 5 and 50 nanometers.

18. The invention of claim 1 wherein said lithium-alloying particle is a nanoparticle having a mean linear dimension of between 5 and 20 nanometers.

19. The invention of claim 15 wherein said expansion accommodation pore has a mean linear dimension of between 2 nanometers and 5 microns.

20. The invention of claim 16 wherein said expansion accommodation pore has a mean linear dimension of between 10 nanometers and 2.5 microns.

21. The invention of claim 17 wherein said expansion accommodation pore has a mean linear dimension of between 10 and 250 nanometers.

22. The invention of claim 18 wherein said expansion accommodation pore has a mean linear dimension of between 10 and 100 nanometers.

23. The invention of claim 1 further comprising a plurality of said composite particles bound together within an electrode matrix.

24. The invention of claim 23 wherein said plurality of composite particles are bound together within said electrode matrix using a method selected from the group consisting of:

encapsulation, entanglement, chemical bonding and combinations thereof.

25. The invention of claim 1 wherein said lithium-alloying particle is bound within said expansion accommodation pore using a method selected from the group consisting of:

encapsulation, entanglement, chemical bonding and combinations thereof.

26. The invention of claim 2 wherein the mean linear dimension of said expansion accommodation pore is 2 to 5 times the mean linear dimension of said unlithiated lithium-alloying particle.

27. The invention of claim 2 wherein the mean linear dimension of said expansion accommodation pore is 2 to 4 times the mean linear dimension of said unlithiated lithium-alloying particle.

28. The invention of claim 2 wherein the mean linear dimension of said expansion accommodation pore is 2 to 3 times the mean linear dimension of said unlithiated lithium-alloying particle.