Porous silicon particulates with micropores and mesopores within macropores

• US 9,947,918 B2
• Filed: 05/05/2016
• Issued: 04/17/2018
• Est. Priority Date: 01/07/2013
• Status: Active Grant

• Current Assignee: Lockheed Martin Corporation (Martin Marietta Corporation), Rice University
• Original Assignee: Lockheed Martin Corporation (Martin Marietta Corporation), Rice University
• Inventors: Biswal, Sibani Lisa, Wong, Michael S., Thakur, Madhuri, Sinsabaugh, Steven L.
• Primary Examiner(s): USYATINSKY, ALEXANDER
• Application Number:
  US15/147,567
• Publication Number:
  US 20160293935A1
• Time in Patent Office: 712 Days
• CPC Class Codes: C01B 33/02 Silicon forming single crystals or homogeneous polycrystalline material with defined structure C30B
• CPC Class Codes: C01P 2004/61 Micrometer sized, i.e. from 1-100 micrometer
• CPC Class Codes: C01P 2006/16 Pore diameter
• CPC Class Codes: C25F 3/12 of semiconducting materials
• 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 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 4/366 as layered products
• CPC Class Codes: H01M 4/386 Silicon or alloys based on silicon
• CPC Class Codes: H01M 4/621 Binders
• CPC Class Codes: H01M 4/622 being polymers
• CPC Class Codes: H01M 4/626 Metals
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 20/133 Renewable energy sources, e.g. sunlight

Abstract

Embodiments of the present disclosure pertain to porous silicon particulates and anode materials that contain them. In some embodiments, each of the porous silicon particulates include a plurality of macropores, mesopores and micropores such that the micropores and mesopores are within the macropores. The porous silicon particulates also contain: a coating associated with the porous silicon particulates; and a binding material associated with the porous silicon particulates. The binding material can include binders, carbon materials, polymers, metals, additives, carbohydrates, and combinations thereof.

Claims

1. An anode material comprising:

porous silicon particulates,

wherein each of the porous silicon particulates comprise a plurality of macropores, mesopores and micropores,

wherein the micropores and mesopores are within the macropores, and

wherein the micropores and mesopores within the macropores provide a textured surface on the silicon particulates;

a coating associated with the porous silicon particulates; and

a binding material associated with the porous silicon particulates, wherein the binding material is selected from the group consisting of carbon materials, polymers, metals, carbohydrates, and combinations thereof.

2. The anode material of claim 1, wherein the coating comprises a metal coating.

3. The anode material of claim 2, wherein the metal is selected from the group consisting of silver, copper, chromium, gold, aluminum, tantalum, lead, zinc, silicon, and combinations thereof.

4. The anode material of claim 2, wherein the metal is silver.

5. The anode material of claim 1, wherein the binding material comprises a polymer selected from the group consisting of polyacrylonitrile (PAN), pyrolyzed polyacrylonitrile (PPAN), polyvinylidene difluoride (PVDF), polyacrylic acid (PAA), carboxymethyl cellulose (CMC), and combinations thereof.

6. The anode material of claim 1, wherein the binding material comprises carbonized polyacrylonitrile.

7. The anode material of claim 1, wherein the plurality of pores comprise hierarchical pores.

8. The anode material of claim 1, wherein the porous silicon particulates have thicknesses ranging from about 10 micrometers to about 200 micrometers.

9. The anode material of claim 1, wherein the porous silicon particulates comprise pores that span at least 50% of a thickness of the porous silicon particulates.

10. The anode material of claim 1, wherein the porous silicon particulates comprise pores that span an entire thickness of the porous silicon particulates.

11. The anode material of claim 1, wherein the porous silicon particulates comprise diameters from about 1 μ

m to about 50 μ

m.

12. The anode material of claim 1, wherein the anode material has a discharge capacity of at least about 600 mAh/g over at least 50 cycles.

13. The anode material of claim 1, wherein the anode material has a discharge capacity of at least about 1000 mAh/g over at least 50 cycles.

14. The anode material of claim 1, wherein the anode material has a Coulombic efficiency of at least about 90% over at least 50 cycles.

15. The anode material of claim 1, wherein the anode material is utilized as part of a lithium ion battery.