METHOD OF FABRICATING FIBRES COMPOSED OF SILICON OR A SILICON-BASED MATERIAL AND THEIR USE IN LITHIUM RECHARGEABLE BATTERIES

• US 20140045062A1
• Filed: 10/16/2013
• Published: 02/13/2014
• Est. Priority Date: 01/23/2006
• Status: Active Grant

• Current Assignee: Nexeon Limited
• Original Assignee: Nexeon Limited
• Inventors: Green, Mino, Liu, Feng-Ming
• Granted Patent: US 9,583,762 B2
• Time in Patent Office: Days
• US Class Current: 429/211
• CPC Class Codes: C30B 29/06 Silicon
• CPC Class Codes: C30B 29/60 characterised by shape
• CPC Class Codes: C30B 33/08 Etching
• 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 4/0402 Methods of deposition of the material
• 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 4/133 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 4/1393 of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/1395 of electrodes based on metals, Si or alloys
• CPC Class Codes: H01M 4/386 Silicon or alloys based on silicon
• CPC Class Codes: H01M 4/5825 Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• 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
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

An electrically interconnected mass includes elongated structures. The elongated structures are electrochemically active and at least some of the elongated structures cross over each other to provide intersections and a porous structure. The elongated structures include doped silicon.

Claims

1-35. -35. (canceled)

36. A method of forming a porous structure comprising a plurality of silicon-comprising elongated elements, the method comprising:

arranging a plurality of silicon-comprising elongated elements to form a porous structure, wherein at least some of the elongated elements cross over each other to provide multiple intersections; and

charging the porous structure to form disrupted crystalline or amorphous structures at the intersections wherein the charging welds the elongated elements to one another at the intersections.

37. A method of forming a porous structure as claimed in claim 36, the method further comprising:

etching a silicon or silicon-based substrate to form elongate elements.

38. A method of forming a porous structure as claimed in claim 36, the method further comprising:

detaching elongated elements from a substrate.

39. A method of forming a porous structure as claimed in claim 36 wherein the elongated structures are capable of lithium insertion and removal.

40. A method of forming a porous structure as claimed in claim 36 wherein the porous structure has a percentage pore volume of about 10-30 per cent.

41. A method of forming a porous structure as claimed in claim 36 wherein the elongated elements have a resistivity of 100 to 0.001 Ohm cm.

42. A method of forming a porous structure as claimed in claim 36 wherein the elongated elements have an aspect ratio of greater than 40:

1.

43. A method of forming a porous structure as claimed in claim 36 wherein the elongated elements comprise n-type and/or p-type silicon.

44. A method of forming a porous structure as claimed in claim 36 wherein the elongated elements have a transverse dimension in the range 0.08 to 0.5 microns and/or a length in the range of 20 to 300 microns.

45. A method of forming a porous structure as claimed in claim 36, the method further comprising:

mixing the porous structure with at least one of a binder and an electronic additive.

46. A method of forming a lithium-ion battery electrode, the method comprising the method of forming a porous structure as claimed in claim 36 and further comprising:

at least partially filling the porous structure with electrolyte.

47. A method of making a lithium-ion battery comprising the steps of claim 36.

48. A porous structure comprising a plurality of silicon-comprising elongated elements,

wherein at least some of the elongated elements cross over each other to provide multiple intersections,

wherein the intersections comprise a disrupted crystalline or amorphous structure, formed by charging the porous structure, which welds elongated elements to one another.

49. A porous structure as claimed in claim 48 wherein the elongated elements are capable of lithium insertion and removal.

50. A porous structure as claimed in claim 48 having a percentage pore volume of about 10-30 per cent.

51. A porous structure as claimed in claim 48 wherein the elongated elements have an aspect ratio of greater than 40:

1.

52. A porous structure as claimed in claim 48 wherein the elongated elements comprise n-type and/or p-type silicon.

53. A porous structure as claimed in claim 48 wherein the elongated elements have a transverse dimension in the range 0.08 to 0.5 microns and/or a length in the range of 20 to 300 microns.

54. A porous structure as claimed in claim 48 further comprising at least one of a binder and an electronic additive.

55. A lithium-ion battery electrode comprising the porous structure of claim 48.

56. A method of forming a lithium-ion battery electrode, the method comprising:

depositing a plurality of crystalline elongated elements to form a porous structure, wherein at least some of the elongated elements cross over each other to form intersections comprising a disrupted crystalline structure; and

charging the porous structure to form amorphous structures at the intersections wherein the charging welds the elongated elements to one another at the intersections.