Silicon anode for a rechargeable battery

• US 9,871,249 B2
• Filed: 01/15/2016
• Issued: 01/16/2018
• Est. Priority Date: 05/11/2007
• Status: Expired due to Fees

• Current Assignee: Nexeon Limited
• Original Assignee: Nexeon Limited
• Inventors: Green, Mino
• Primary Examiner(s): AMPONSAH, OSEI K
• Application Number:
  US14/997,107
• Publication Number:
  US 20160248088A1
• Time in Patent Office: 732 Days
• CPC Class Codes: H01M 10/052 Li-accumulators
• 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 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 2004/028 Positive electrodes
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• 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 4/485 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 4/525 of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An electrode and electrode assembly, for example for use as an anode in a lithium-ion rechargeable cell that uses silicon or silicon-based elements of specific dimensions and geometry as its active material, is provided, as well as methods for manufacturing the same. The active silicon or silicon-based material may include fibers, sheets, flakes, tubes or ribbons, for example.

Claims

1. An electrode comprising an active material comprising a plurality of silicon or silicon-based elements, each element having a first dimension in the range of 0.08 μ

m to 0.3 μ

m and a second dimension oriented generally transverse to the first dimension, the second dimension being at least five times as large as the first dimension,

wherein the elements form an interconnected array,

wherein the elements are capable of lithium insertion and removal, and

wherein the elements are selected from the group consisting of, ribbons and flakes, and

wherein the elements have a third dimension oriented transverse to each of the first and second dimensions, the third dimension being at least ten times as large as the first dimension.

2. An electrode according to claim 1 wherein the first dimension is in the range of 0.2 μ

m to 0.3 μ

m.

3. The electrode according to claim 1, wherein the second dimension is at least ten times as large as the first dimension.

4. The electrode according to claim 1, wherein the third dimension is at least 100 times as large as the first dimension.

5. The electrode according to claim 1, wherein the elements have a largest dimension that is no larger than 500 μ

m.

6. The electrode according to claim 1, wherein the elements are elongate.

7. The electrode according to claim 1, wherein the silicon or silicon-based elements are ribbons.

8. The electrode according to claim 1, wherein the silicon or silicon-based elements are flakes.

9. The electrode according to claim 1, wherein the elements of the interconnected array form multiple connections therebetween.

10. The electrode according to claim 1, wherein the elements of the interconnected array criss-cross one another.

11. The electrode according to claim 1, wherein the active material has a pore volume between 10% and 30%.

12. The electrode according to claim 1, wherein the active material has a pore volume, the pore volume being saturated with a liquid electrolyte.

13. An electrochemical cell comprising the electrode as claimed in claim 1 configured as an anode, and a cathode comprising an active material comprising a lithium-based metal oxide.

14. A lithium-ion rechargeable battery comprising the electrochemical cell according to claim 13.

15. A device comprising the electrochemical cell according to claim 13, the electrochemical cell being configured to power the device.