IP Library › Granted Patent US 12,418,023
Granted Patent B2
US 12,418,023 · App. 17/960,707 · Granted Sep 16, 2025

Composite carbon materials comprising lithium alloying electrochemical modifiers

Inventors: Avery J. Sakshaug (Everett, WA); Leah A. Thompkins (Seattle, WA); Henry R. Costantino (Woodinville, WA); Aaron M. Feaver (Seattle, WA)
Assignee: Group14 Technologies, Inc.
H01M4/366H01G11/06H01G11/32H01G11/50H01M4/0471H01M4/133H01M4/134H01M4/1393H01M4/1395H01M4/362H01M4/364H01M4/386H01M4/587H01M4/625H01M10/0525H01M4/387H01M4/483Y02E60/13Y02T10/70
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Quick Facts
Patent No.
US 12,418,023
App. No.
17/960,707
Granted
Sep 16, 2025
Kind
B2
Abstract

The present application is generally directed to composites comprising a hard carbon material and an electrochemical modifier. The composite materials find utility in any number of electrical devices, for example, in lithium ion batteries. Methods for making the disclosed composite materials are also disclosed.

Claims (24)

1. A composite material having a first cycle insertion of at least 700 mAh/g and a first cycle efficiency in the absence of ex situ prelithiation of greater than 70% when the composite material is incorporated into an electrode of a lithium based energy storage device, wherein:

the composite material comprises an amorphous pyrolyzed and activated porous carbon material and a lithium alloying electrochemical modifier;

the amorphous pyrolyzed and activated porous carbon material is microporous such that greater than 95% of total pore volume resides in pores having a diameter of 1 nm or less;

the lithium alloying electrochemical modifier is encapsulated within micropores of the amorphous pyrolyzed and activated porous carbon material; and

the amorphous pyrolyzed and activated porous carbon material has a total pore volume ranging from 0.6 cc/g to 1.0 cc/g.

2. The composite material of claim 1 , wherein the first cycle insertion is at least 1000 mAh/g and the first cycle efficiency in the absence of ex situ prelithiation is greater than 80%.

3. The composite material of claim 1 , wherein the first cycle insertion is at least 2400 mAh/g and the first cycle efficiency in the absence of ex situ prelithiation is greater than 80%.

4. The composite material of claim 1 , wherein the first cycle efficiency in the absence of ex situ prelithiation is greater than 90%.

5. The composite material of claim 1 , wherein the composite has a first cycle extraction of at least 600 mAh/g and a fifth cycle retention of greater than 99% when the composite material is incorporated into the electrode of the lithium based energy storage device.

6. The composite material of claim 5 , wherein the first cycle extraction is at least 1200 mAh/g.

7. The composite material of claim 1 , wherein the lithium alloying electrochemical modifier is silicon, tin, germanium, nickel, aluminum, manganese, Al 2 O 3 , titanium, titanium oxide, sulfur, molybdenum, arsenic, gallium, phosphorous, selenium, antimony, bismuth, tellurium or indium or combinations thereof.

8. The composite material of claim 7 , wherein the lithium alloying electrochemical modifier is silicon.

9. The composite material of claim 1 , wherein the electrochemical modifier comprises nanoparticles.

10. The composite material of claim 1 , wherein a ratio of carbon material to electrochemical modifier ranges from 40:1 to 1:99 on a mass basis.

11. The composite material of claim 1 , wherein a ratio of carbon material to electrochemical modifier ranges from 19:1 to 1:9 on a mass basis.

12. The composite material of claim 1 , wherein the composite material further comprises an efficiency enhancing electrochemical modifier.

13. The composite material of claim 12 , wherein the efficiency enhancing electrochemical modifier comprises phosphorus and is present in the composite material at 3-13% as measured by TXRF.

14. The composite material of claim 1 , wherein the composite material comprises a total of less than 200 ppm of all elements having atomic numbers ranging from 11 to 92, excluding any intentionally added electrochemical modifier, as measured by TXRF.

15. The composite material of claim 1 , wherein the carbon material is a hard carbon material.

16. A composite material having a first cycle extraction of at least 1900 mAh/g and a first cycle efficiency in the absence of ex situ prelithiation of greater than 80% when the composite material is incorporated into an electrode of a lithium based energy storage device, wherein:

the composite material comprises an amorphous pyrolyzed and activated porous carbon material and silicon in a ratio ranging from 19:1 to 1:9 on a mass basis;

the porous carbon material has a total pore volume ranging from 0.6 cc/g to 1.0 cc/g, and is microporous such that greater than 95% of total pore volume resides in pores having a diameter of 1 nm or less;

the silicon is encapsulated within micropores of the amorphous pyrolyzed and activated porous carbon material; and

the composite material further comprises 3-13% phosphorus.

Continuity (7)
Continuation 16894582 · Jun 5, 2020
Continuation 16406971 · May 8, 2019
Continuation 15675462 · Aug 11, 2017
Continuation 14084469 · Nov 19, 2013
Provisional Application 61834258 · Jun 12, 2013
Provisional Application 61786165 · Mar 14, 2013
Related Publication 20230115078A1 · Apr 13, 2023
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