Materials with extremely durable intercalation of lithium and manufacturing methods thereof
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.
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 0.5 cm 3 /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 m 2 /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 m 2 /g.
4. The material of claim 1 , wherein the composite particles have a surface area below 30 m 2 /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 0.5 cm 3 /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 m 2 /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 m 2 /g.
12. The material of claim 9 , wherein the composite particles have a surface area below 30 m 2 /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 optionally mesopores, and having:
(i) a total pore volume of greater than 0.5 cm 3 /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 m 2 /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 m 2 /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 0.5 cm 3 /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 m 2 /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 m 2 /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 .