Granted Patent B2

US 12,424,663 · App. 17/528,987 · Granted Sep 23, 2025

Inventors: Heidi Leighette Anderson (Irvine, CA); Benjamin Yong Park (Irvine, CA); Hong Gan (Irvine, CA); Sung Won Choi (Irvine, CA)

Assignee: Enevate Corporation

H01M10/0569H01M10/052H01M2300/0034H01M2300/0037

Abstract

Claims (28)

1. A composite material comprising:

more than about 50% by weight of silicon particles;

with the remainder being one or more types of carbon phases, wherein at least one of the one or more types of carbon phases is a continuous phase that holds the composite material together such that the silicon particles are distributed throughout the composite material; and

wherein the silicon particles are in contact with the continuous phase;

and wherein the silicon particles have an average largest dimension between about 5 μm and about 40 μm.

2. The composite material of claim 1 , wherein the at least one of the one or more types of carbon phases that is a continuous phase comprises pyrolytic carbon.

3. The composite material of claim 1 , wherein the one or more types of carbon phases comprises graphite particles.

4. The composite material of claim 1 , further comprising conductive particles.

5. The composite material of claim 1 , further comprising metal particles.

6. The composite material of claim 1 , wherein the composite material is electrochemically active.

7. The composite material of claim 1 , wherein the silicon particles are homogenously distributed throughout the composite material.

8. A battery electrode comprising the composite material of claim 1 .

9. A method of forming the composite material of claim 1 comprising:

providing a mixture comprising a precursor and silicon particles; and

pyrolysing the precursor to convert the precursor into the one or more types of carbon phases to form the composite material.

10. The method of claim 9 , wherein the at least one of the one or more types of carbon phases that is a continuous phase comprises pyrolytic carbon.

11. The method of claim 9 , wherein the mixture further comprises a solvent.

12. The method of claim 9 , wherein the precursor comprises a polyimide.

13. The method of claim 9 , wherein the precursor comprises a phenolic resin.

14. The method of claim 9 , wherein the precursor comprises a hydrocarbon compound.

15. The method of claim 9 , further comprising:

casting the mixture on a substrate;

drying the mixture to form a film;

removing the film from the substrate; and

curing the film in a hot press.

16. The method of claim 9 , further comprising forming a battery electrode from the composite material.

17. The composite material of claim 1 , wherein the silicon particles have an average largest dimension between about 5 μm and about 30 μm.

18. The composite material of claim 1 , wherein the silicon particles have an average largest dimension between about 5 μm and about 20 μm.

Assignments (2)

Continuity (9)

References Cited (203)