Materials with extremely durable intercalation of lithium and manufacturing methods thereof

• US 10,608,254 B2
• Filed: 10/21/2019
• Issued: 03/31/2020
• Est. Priority Date: 08/28/2015
• Status: Active Grant

• Current Assignee: Group14 Technologies Inc.
• Original Assignee: Group14 Technologies Inc.
• Inventors: Sakshaug, Avery J., Costantino, Henry R., Feaver, Aaron M., Thompkins, Leah A., Geramita, Katharine, Kron, Benjamin E., Fredrick, Sarah, Afkhami, Farshid, Strong, Adam
• Primary Examiner(s): Barcena, Carlos
• Application Number:
  US16/659,373
• Publication Number:
  US 20200075954A1
• Time in Patent Office: 162 Days
• CPC Class Codes: C04B 2111/00853 in electrochemical cells or batteries, e.g. fuel cells
• CPC Class Codes: C04B 2235/428 Silicon
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/6581 Total pressure below 1 atmosphere, e.g. vacuum
• CPC Class Codes: C04B 35/522 Graphite C04B35/536 takes precedence
• CPC Class Codes: C04B 35/524 obtained from polymer precursors, e.g. glass-like carbon material
• CPC Class Codes: C04B 38/0051 characterised by the pore size, pore shape or kind of porosity
• CPC Class Codes: C04B 38/0054 the pores being microsized or nanosized
• CPC Class Codes: C04B 38/0064 Multimodal pore size distribution
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4529 applied from the gas phase
• CPC Class Codes: C04B 41/5096 Silicon C04B35/573 takes precedence
• CPC Class Codes: C04B 41/85 with inorganic materials
• CPC Class Codes: H01B 1/04 mainly consisting of carbon-silicon compounds, carbon or silicon
• 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 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 4/0416 involving impregnation with a solution, dispersion, paste or dry powder H01M4/0438 takes precedence
• CPC Class Codes: H01M 4/133 Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/134 Electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/362 : Composites
• CPC Class Codes: H01M 4/364 : as mixtures
• 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 4/587 : for inserting or intercalating light metals
• CPC Class Codes: H01M 4/625 : Carbon or graphite
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries

Abstract

Composites of silicon and various porous scaffold materials, such as carbon material comprising micro-, meso- and/or macropores, and methods for manufacturing the same are provided. The compositions find utility in various applications, including electrical energy storage electrodes and devices comprising the same.

Claims

1. A material comprising a plurality of composite particles, wherein the composite particles comprise:

(a) a porous carbon framework comprising micropores and mesopores, and having;

(i) a total pore volume of greater than 0.6 cm³/g;

(ii) a volume fraction of micropores in the range from 20-50% and a volume fraction of mesopores in the range of 50-80%;

(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume; and

(iv) a Dv50 ranging from 5 nm to 20 um;

(b) nano-featured silicon embedded within pores of the porous carbon framework, wherein the weight percent of the nano-featured silicon to the porous carbon framework ranges from 10% to 80%, and

(c) a surface area below 50 m²/g.

2. The material of claim 1, wherein the Dv50 ranges from 2 to 20 microns.

3. The material of claim 1, wherein the composite particles have a surface area below 20 m²/g.

4. The material of claim 1, wherein the composite particles have a surface area below 30 m²/g.

5. The material of claim 1, wherein the porous carbon framework has a monomodal pore size distribution.

6. The material of claim 1, wherein the material has a gravimetric capacity between 1200 and 3500 mAh/g when the material is incorporated into an electrode of a lithium based energy storage device.

7. An electrode comprising the material of claim 1 and a binder or a conductive additive, or both.

8. A lithium-based energy storage device comprising the material of claim 1.

9. A material comprising a plurality of composite particles, wherein the composite particles comprise:

(a) a porous carbon framework comprising micropores and mesopores, and having;

(i) a total pore volume of greater than 0.6 cm³/g;

(ii) a volume fraction of micropores in the range from 40-60% and a volume fraction of mesopores in the range of 40-60%;

(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume; and

(iv) a Dv50 ranging from 5 nm to 20 um;

(b) nano-featured silicon embedded within pores of the porous carbon framework, wherein the weight percent of the nano-featured silicon to the porous carbon framework ranges from 10% to 80%, and

(c) a surface area below 50 m²/g.

10. The material of claim 9, wherein the Dv50 ranges from 2 to 20 microns.

11. The material of claim 9, wherein the composite particles have a surface area below 20 m²/g.

12. The material of claim 9, wherein the composite particles have a surface area below 30 m²/g.

13. The material of claim 9, wherein the porous carbon framework has a monomodal pore size distribution.

14. The material of claim 9, wherein the material has a gravimetric capacity between 1200 and 3500 mAh/g when the material is incorporated into an electrode of a lithium based energy storage device.

15. An electrode comprising the material of claim 9 and a binder or a conductive additive, or both.

16. A lithium-based energy storage device comprising the material of claim 9.

17. A material comprising a plurality of composite particles, wherein the composite particles comprise:

(a) a porous carbon framework comprising micropores and mesopores, and having;

(i) a total pore volume of greater than 0.6 cm³/g;

(ii) a volume fraction of micropores in the range from 80-95% and a volume fraction of mesopores in the range of 0-10%;

(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume; and

(iv) a Dv50 ranging from 5 nm to 20 um;

(b) nano-featured silicon embedded within pores of the porous carbon framework, wherein the weight percent of the nano-featured silicon to the porous carbon framework ranges from 10% to 80%, and

(c) a surface area below 50 m²/g.

18. The material of claim 17, wherein the Dv50 ranges from 2 to 20 microns.

19. The material of claim 17, wherein the composite particles have a surface area below 30 m²/g.

20. The material of claim 17, wherein the porous carbon framework has a monomodal pore size distribution.

21. The material of claim 17, wherein the material has a gravimetric capacity between 1200 and 3500 mAh/g when the material is incorporated into an electrode of a lithium based energy storage device.

22. An electrode comprising the material of claim 17 and a binder or a conductive additive, or both.

23. A lithium-based energy storage device comprising the material of claim 17.

24. A material comprising a plurality of composite particles, wherein the composite particles comprise:

(a) a porous carbon framework having;

(i) a total pore volume of greater than 0.6 cm³/g;

(ii) a volume fraction of micropores greater than 50%;

(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume; and

(iv) a Dv50 ranging from 5 nm to 20 um;

(b) nano-featured silicon embedded within pores of the porous carbon framework, wherein the weight percent of the nano-featured silicon to the porous carbon framework ranges from 10% to 80%, and

(c) a surface area below 50 m²/g.

25. The material of claim 24, wherein the Dv50 ranges from 2 to 20 microns.

26. The material of claim 24, wherein the composite particles have a surface area below 30 m²/g.

27. The material of claim 24, wherein the porous carbon framework has a monomodal pore size distribution.

28. The material of claim 24, wherein the material has a gravimetric capacity between 1200 and 3500 mAh/g when the material is incorporated into an electrode of a lithium based energy storage device.

29. An electrode comprising the material of claim 24 and a binder or a conductive additive, or both.

30. A lithium-based energy storage device comprising the material of claim 24.