Silicon-graphene nanocomposites for electrochemical applications

1. A nanographitic composite comprising:

a plurality of composite particles, each composite particle comprising:

an electroactive particle of one of: an alloy or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, or Cd; an oxide, carbide, nitride, sulfide, phosphide, selenide, telluride, antimonide, or their mixtures of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, or Cd; or one or more metals of silicon, tin, iron, magnesium, aluminum, lead, gold, silver, titanium, platinum, palladium, ruthenium, copper, nickel, rhodium and nickel and combinations thereof;

a coating layer comprising an inner film comprising graphene that is bound by covalent or interdiffusion bonding to the electroactive particle and an outer layer of graphene nanoplatelets disposed over the inner film comprising the graphene

wherein the outer layer of the graphene nanoplatelets has a longest lateral dimension that is less than a longest lateral dimension of the electroactive particle, and

wherein the outer layer of the graphene nanoplatelets is configured to accommodate a volume change in the electroactive particle and the graphene nanoplatelets are not strictly planar to a surface of the electroactive particle and take on a range of orientations.

2. The nanographitic composite of claim 1 , wherein the inner film additionally comprises a mixture of carbon and silicon.

3. The nanographitic composite of claim 1 , wherein the inner film has a thickness in the range of 1-25 nm.

4. The nanographitic composite of claim 1 , wherein the inner film is integral with the electroactive particle.

5. The nanographitic composite of claim 1 , wherein the inner film is crystalline.

6. The nanographitic composite of claim 1 , wherein the inner film is disordered or amorphous.

7. The nanographitic composite of claim 1 , wherein the electroactive particle comprises silicon and the inner film additionally comprises a SiC intermetallic.

8. The nanographitic composite of claim 1 , wherein the inner film is covalently bonded to the electroactive particle.

9. The nanographitic composite of claim 8 wherein the covalent bond is a pi-bond or a partial pi-bond.

10. The nanographitic composite of claim 1 wherein the electroactive particle comprises silicon and the silicon and an additional carbon of the inner film form a compositional gradient across its thickness.

11. The nanographitic composite of claim 1 , wherein the plurality of composite particles form agglomerates.

12. The nanographitic composite of claim 1 , wherein the graphene nanoplatelets have a thickness of 0.34 nm to 50 nm and lateral dimensions of less than 900 nm.

13. The nanographitic composite of claim 1 , wherein the outer layer of graphene nanoplatelets comprises multiple layers of graphene nanoplatelets.

14. The nanographitic composite of claim 1 , wherein the electroactive particle is the one or more metals.

15. The nanographitic composite of claim 1 , wherein electroactive particle comprises silicon.

16. The nanographitic composite of claim 15 , wherein the silicon is present in a range from 10 wt % to 90 wt % of the composite particle.

17. The nanographitic composite of claim 16 , wherein the composite particle further comprises a conductive carbon additive.

18. The nanographitic composite of claim 17 , wherein the conductive carbon additive is selected from the group consisting of carbon black, acetylene black, carbon nanotube, carbon fiber, carbon nanohorn, carbon nanocoil and combinations thereof.

19. The nanographitic composite of claim 1 , wherein the composite particle has a tap density of greater than 0.50 g/cm 3 .

20. The nanographitic composite of claim 1 , wherein the composite particle has a tap density of greater than 0.8 g/cm 3 .

21. The nanographitic composite of claim 15 , wherein the silicon is present in a range from 40 wt % to 70 wt % of the composite particle.

22. The nanographitic composite of claim 1 , wherein the outer layer of graphene nanoplatelets are associated with the inner film through van der Waals attraction.

23. The nanographitic composite of claim 1 , wherein graphene nanoplatelets in the outer layer comprises graphene nanoplatelets having a longest lateral dimension that is less than 50% of a longest lateral dimension the electroactive particle.

24. The nanographitic composite of claim 1 , wherein graphene nanoplatelets in the outer layer comprises graphene nanoplatelets having a longest lateral dimension that is less than 25% of a longest lateral dimension the electroactive particle.

25. The nanographitic composite of claim 1 , wherein the graphene nanoplatelets of the outer layer comprises tangled graphene.

26. The nanographitic composite of claim 1 , wherein the graphene nanoplatelets of the outer layer comprises stretched graphene.

27. The nanographitic composite of claim 1 , wherein the graphene nanoplatelets have a longest lateral dimension of less than 500 nm.

28. The nanographitic composite of claim 1 , wherein the graphene nanoplatelets have a longest lateral dimension in the range of 10 nm-700 nm.

29. The nanographitic composite of claim 1 , wherein the graphene nanoplatelets have a longest lateral dimension in the range of 30 nm to 200 nm.

30. An electrode for use as an anode in a lithium ion battery, said electrode comprising:

(a) the nanographitic composite according to claim 1 ; and

(b) a binder.

31. The electrode of claim 30 , further comprising a conductive additive.

32. The electrode of claim 31 , wherein the conductive additive comprises a graphene.

33. The electrode of claim 31 , wherein the conductive additive is 2 to 20 wt % of the total electrode weight.

34. The electrode of claim 30 , wherein the binder is 3 to 20 wt % of the total electrode weight.

35. A lithium ion battery comprising:

an anode according to claim 30 ;

a cathode;

a separator spacing apart the anode and the cathode; and

an electrolyte in contact with the anode and the cathode.