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 cm3/g,
(ii) a volume fraction of macropores in the range from 0-10%, and
(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 75% of the total pore volume;
(b) a Dv0 ranging from 1 nm to 5 um;
(c) a Dv50 ranging from 5 nm to 20 um;
(d) a Dv100 ranging from 8 nm to 100 um; and
(e) silicon embedded within pores of the porous carbon framework, wherein the weight percent of the silicon ranges from 10% to 80%.
2. The material of claim 1 , wherein total pore volume is greater than 0.6 cm3/g.
3. The material of claim 1 , wherein at least 75% of the total pore volume of the porous carbon framework comprises pores at or below 1 nm.
4. The material of claim 1 , wherein the weight percent of the silicon ranges from 20% to 70%.
5. The material of claim 1 , wherein the weight percent of the silicon ranges from 30% to 60%.
6. The material of claim 1 , wherein the particle has a size span ((D90−D10)/D50) of 5 or less.
7. The material of claim 1 , wherein the silicon embedded within the pores of the porous carbon framework fills 10-90% of the total pore volume.
8. The material of claim 1 , wherein the silicon embedded within the pores of the porous carbon framework fills 20-80% of the total pore volume.
9. The material of claim 1 , wherein the silicon embedded within the pores of the porous carbon framework fills 30-70% of the total pore volume.
10. The material of claim 1 , further comprising a surface area below 50 m2/g.
11. The material of claim 1 , wherein the composite particles further comprise a carbon surface coating.
12. The material of claim 11 , wherein the carbon surface coating is deposited from a deposition gas via by hydrocarbon vapor deposition.
13. The material of claim 12 , wherein the deposition gas is one or more of: methane, propane, butane, acetylene, cyclohexane, ethane, or propylene.
14. 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 cm3/g,
(ii) a volume fraction of macropores in the range from 0-10%, and
(iii) a fractional pore volume of pores at or below 10 nm that comprises at least 50% of the total pore volume;
(b) a Dv0 ranging from 1 nm to 5 um;
(c) a Dv50 ranging from 5 nm to 20 um;
(d) a Dv100 ranging from 8 nm to 100 um; and
(e) silicon embedded within pores of the porous carbon framework, wherein the weight percent of the silicon ranges from 10% to 80%.
15. The material of claim 14 , wherein total pore volume is greater than 0.6 cm3/g.
16. The material of claim 14 , wherein at least 50% of the total pore volume of the porous carbon framework comprises pores at or below 1 nm.
17. The material of claim 14 , wherein the weight percent of the silicon ranges from 20% to 70%.
18. The material of claim 14 , wherein the weight percent of the silicon ranges from 30% to 60%.
19. The material of claim 14 , wherein the particle has a size span ((D90−D10)/D50) of 5 or less.
20. The material of claim 14 , wherein the silicon embedded within the pores of the porous carbon framework fills 10-90% of the total pore volume.
21. The material of claim 14 , wherein the silicon embedded within the pores of the porous carbon framework fills 20-80% of the total pore volume.
22. The material of claim 14 , wherein the silicon embedded within the pores of the porous carbon framework fills 30-70% of the total pore volume.
23. The material of claim 14 , further comprising a surface area below 50 m2/g.
24. The material of claim 14 , wherein the composite particles further comprise a carbon surface coating.
25. The material of claim 24 , wherein the carbon surface coating is deposited from a deposition gas via by hydrocarbon vapor deposition.
26. The material of claim 25 , wherein the deposition gas is one or more of: methane, propane, butane, acetylene, cyclohexane, ethane, or propylene.