Method of making silicon anode material for rechargeable cells
First Claim
1. An electroactive material comprising silicon structures, whereinthe silicon structures have been at least partially isolated from a solidified aluminum-based metal-silicon alloy comprising less than 30 wt % silicon, the solidified aluminum-based metal-silicon alloy comprising an aluminum-based metal and the silicon structures dispersed therein, the silicon structures having been at least partially isolated from the aluminum-based metal of the alloy by selective etching of the aluminum-based metal of the alloy, andthe silicon structures comprise silicon-comprising structural elements, wherein 30 to 100% of the structural elements are high-aspect ratio structural elements having a minor dimension of less than 2 μ
- m and a length of greater than 5 times the minor dimension.
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Abstract
There is provided a method of forming silicon anode material for rechargeable cells. The method includes providing a metal matrix, comprising no more than 30 wt % silicon, including silicon structures dispersed therein. The method further includes at least partially etching the metal matrix to at least partially isolate the silicon structures.
168 Citations
29 Claims
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1. An electroactive material comprising silicon structures, wherein
the silicon structures have been at least partially isolated from a solidified aluminum-based metal-silicon alloy comprising less than 30 wt % silicon, the solidified aluminum-based metal-silicon alloy comprising an aluminum-based metal and the silicon structures dispersed therein, the silicon structures having been at least partially isolated from the aluminum-based metal of the alloy by selective etching of the aluminum-based metal of the alloy, and the silicon structures comprise silicon-comprising structural elements, wherein 30 to 100% of the structural elements are high-aspect ratio structural elements having a minor dimension of less than 2 μ - m and a length of greater than 5 times the minor dimension.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 24, 25, 26, 27, 28)
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17. An electroactive material, made by a method which comprises:
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providing a metal-silicon alloy comprising less than 30 wt % silicon, comprising an aluminum-based metal matrix, including an aluminum-based metal and silicon structures dispersed therein, the silicon structures comprising elongate structural elements having a minor dimension of less than 2 μ
m and an aspect ratio of at least 5; andselectively etching the aluminum-based metal of the aluminum-based metal matrix to at least partially isolate the silicon structures, to provide silicon structures comprising an agglomeration of the elongate structural elements. - View Dependent Claims (23, 29)
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18. An electroactive material, comprising silicon-comprising structural elements, the silicon-comprising structural elements comprising high-aspect ratio structural elements having a minor dimension of less than 2 μ
- m and a length of greater than 5 times the minor dimension, the silicon-comprising structural elements being integrally connected to form a porous structure, and which further comprises residual metal, the residual metal comprising aluminum, an aluminum silicide intermetallic, or a combination thereof.
- View Dependent Claims (19, 20, 21, 22)
Specification