Electrode comprising structured silicon-based material

• US 9,012,079 B2
• Filed: 07/17/2008
• Issued: 04/21/2015
• Est. Priority Date: 07/17/2007
• Status: Active Grant

• Current Assignee: Nexeon Limited
• Original Assignee: Nexeon Limited
• Inventors: Green, Mino
• Primary Examiner(s): Cano, Milton I
• Assistant Examiner(s): VO, JIMMY
• Application Number:
  US12/669,203
• Publication Number:
  US 20100190057A1
• Time in Patent Office: 2,469 Days
• Field of Search: 429/209, 429/218.1, 429/231.95, 429/226, 429/219, 429/221, 429/223, 429/225
• US Class Current: 429/218.1
• 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 2004/027 Negative electrodes
• CPC Class Codes: H01M 4/0492 Chemical attack of the support material
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/1395 of 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 4/485 of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy H01M4/505, H01M4/525 take precedence
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/662 Alloys collectors of lead alloys H01M4/685
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A composite electrode includes an active component directly bonded to a current collector. The direct bonding provides a low resistance contact between the current collector and the active material. The active component can be provided as fibers of silicon. The fibers can be free or attached to a support.

Claims

1. An electrode comprising an active component directly bonded to a current collector, wherein the active component comprises silicon-comprising fibres arranged in a felt-like structure in which the fibres cross over to provide multiple intersections, such that the fibres contact others of the fibres a plurality of times along their lengths and the direct bonding is via a compound formed from the active component and the current collector at contacting surfaces of the active component and the current collector.

2. The electrode as claimed in claim 1 wherein the active component comprises one or more of silicon, aluminium, tin, lead, bismuth, antimony and silver.

3. The electrode as claimed in claim 1 wherein the current collector comprises one or more of copper, nickel, aluminium, iron, iridium, gold, silver or titanium.

4. The electrode as claimed in claim 1 in which the fibres are single crystal fibres.

5. The electrode as claimed in claim 1 in which the fibres are deposited in a composite.

6. The electrode as claimed in claim 1 wherein at least some of the fibres extend from silicon-comprising particles.

7. The electrode as claimed in a claim 1 in which the electrode is an anode.

8. An electrochemical cell containing an anode as claimed in claim 1.

9. The electrochemical cell as claimed in claim 8 in which the cathode comprises a lithium-containing compound capable of releasing and readsorbing lithium ions as its active material.

10. The electrochemical cell as claimed in claim 8 in which the cathode comprises lithium-based metal oxide or phosphate as its active material preferably LiCoO₂ or LiMn_xNi_xCo_1-2xO₂ or LiFePO₄.

11. A cell comprising an anode as claimed in claim 1 and a cathode.

12. A cell as claimed in claim 11 in which the cathode comprises lithium-based material.

13. A cell as claimed in claim 12 in which the cathode comprises lithium cobalt dioxide-based material.

14. A device powered by a cell as claimed in claim 11.

15. The electrode as claimed in claim 1 wherein the fibres comprise n-type or p-type doped silicon.

16. The electrode as claimed in claim 1 wherein the electrode is a composite anode.

17. A lithium-ion battery comprising the electrode as claimed in claim 1 and further comprising a cathode and electrolyte.

18. An electrode comprising an active component directly bonded to a current collector, wherein the active component comprises a plurality of silicon-comprising particles, each particle having a plurality of silicon-comprising fibres extending therefrom, the plurality of silicon-comprising particles being disposed on the current collector such that fibres crossover to provide multiple intersections, such that the fibres contact others of the fibres a plurality of times along their lengths, and the direct bonding is via a compound formed from the active component and current collector at the contacting surfaces of the active component and current collector.

19. The electrode of claim 18 wherein the fibres comprise n-type or p-type doped silicon.

20. The electrode of claim 18 wherein the electrode is a composite anode.

21. A lithium-ion battery comprising the electrode as claimed in claim 18 and further comprising a cathode an electrolyte.