Silicon-containing alloys useful as electrodes for lithium-ion batteries

• US 7,906,238 B2
• Filed: 09/01/2006
• Issued: 03/15/2011
• Est. Priority Date: 12/23/2005
• Status: Active Grant

• Current Assignee: Sicona Battery Technologies Pty Ltd.
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Le, Dinh Ba
• Primary Examiner(s): Kopec; Mark
• Assistant Examiner(s): Nguyen; Haidung D
• Application Number:
  US11/469,561
• Publication Number:
  US 20070148544A1
• Time in Patent Office: 1,656 Days
• Field of Search: 252/516, 252/182.1, 429/231.8, 429/231.95, 429/218.1, 429/231.5, 429/232
• US Class Current: 429/218.1
• CPC Class Codes: B22F 1/08 Metallic powder characterised by particles having an amorphous microstructure
• CPC Class Codes: B22F 2009/043 by ball milling
• CPC Class Codes: B22F 2201/11 Argon
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 9/002 amorphous or microcrystalline
• 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: C22C 1/047 comprising intermetallic compounds C22C1/0441 takes precedence
• 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 10/0569 characterised by the solvents
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• 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 electrode composition for a lithium ion battery having the formula Si_xSn_qM_yC_z where q, x, y, and z represent atomic percent values and (a) (q+x)>2y+z; (b) q≧0, (c) z≧0; and (d) M is one or more metals selected from manganese, molybdenum, niobium, tungsten, tantalum, iron, copper, titanium, vanadium, chromium, nickel, cobalt, zirconium, yttrium, or a combination thereof. The Si, Sn, M, and C elements are arranged in the form of a multi-phase microstructure comprising: (a) an amorphous phase comprising silicon; (b) a nanocrystalline phase comprising a metal silicide; and (c) a phase comprising silicon carbide phase when z>0; and (d) an amorphous phase comprising Sn when q>0.

Claims

1. An electrode composition for a lithium ion battery having the formula Si_xM_yC_z where x, y, and z represent atomic percent values and

(a) x>

2y+z;

(b) x, y and z are greater than 0; and

(c) 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,

wherein the Si, 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 metal silicide; and

(iii) a phase comprising a silicon carbide.

2. An electrode composition according to claim 1 wherein M is one or more metals selected from cobalt, nickel, iron, titanium, molybdenum, tungsten, or combinations thereof.

3. An electrode composition according to claim 1 wherein x≧

60.

4. An electrode composition according to claim 1 wherein z≧

10.

5. An electrode composition according to claim 1 wherein z≧

15.

6. An electrode composition according to claim 1 wherein x≧

60 and M is one or more metals selected from cobalt, nickel, iron, titanium, molybdenum, or combinations thereof.

7. An electrode composition according to claim 6 wherein z≧

10.

8. An electrode composition according to claim 1 wherein M comprises Co.

9. An electrode composition according to claim 8 wherein x≧

60.

10. A lithium ion battery comprising:

an anode;

a cathode; and

an electrolyte,

wherein the anode comprises a composition having the formula Si_xM_yC_z where x, y, and z represent atomic percent values and

(a) x>

2y+z;

(b) x, y, and z are greater than 0; and

(c) 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,

wherein the Si, 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 metal silicide; and

(iii) a phase comprising a silicon carbide.

11. A lithium ion battery according to claim 10 wherein M is one or more metals selected from cobalt, nickel, iron, titanium, molybdenum, tungsten, or combinations thereof.

12. A lithium ion battery according to claim 10 wherein x≧

60.

13. A lithium ion battery according to claim 10 wherein z≧

10.

14. A lithium ion battery according to claim 10 wherein z≧

15.

15. A lithium ion battery according to claim 10 wherein x≧

60 and M is one or more metals selected from cobalt, nickel, iron, titanium, molybdenum, or combinations thereof.

16. A lithium ion battery according to claim 15 wherein z≧

10.

17. A lithium ion battery according to claim 10 wherein M comprises Co.

18. A lithium ion battery according to claim 17 wherein x≧

60.

19. A lithium ion battery according to claim 10 wherein the anode further comprises a binder and a conductive diluent.

20. A lithium ion battery according to claim 19 wherein the binder comprises a polyimide.

21. A lithium ion battery according to claim 19 wherein the conductive diluent comprises carbon black.

22. A lithium ion battery according to claim 10 wherein the electrolyte comprises fluoroethylene carbonate.