# US 11,999,828 B2 · Preparation of polymeric resins and carbon materials

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- Number: US 11,999,828 B2
- Document ID: US11999828B2
- Status: Granted
- Kind: B2
- Application number: 18/456,428
- Filed: 2023-08-25
- Published: 2023-12-14
- Granted: 2024-06-04
- Earliest claimed: 2012-02-09
- Assignees: Group14 Technologies, Inc.
- Applicants: Group14 Technologies, Inc.
- Inventors: Katharine Geramita; Benjamin E. Kron; Henry R. Costantino; Aaron M. Feaver; Avery J. Sakshaug; Leah A. Thompkins; Alan Tzu-Yang Chang
- Web page: https://patentgrep.com/patent/US11999828B2

## CPC

- C08G 8/22: Resorcinol
- C01B 32/05: Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
- C01B 32/30: Active carbon
- C01B 32/312: Preparation
- C01B 32/336: characterised by gaseous activating agents
- H01G 11/34: characterised by carbonisation or activation of carbon
- H01G 11/44: Raw materials therefor, e.g. resins or coal
- H01M 4/133: Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
- H01M 4/14: Electrodes for lead-acid accumulators
- H01M 4/36: Selection of substances as active materials, active masses, active liquids
- H01M 4/587: for inserting or intercalating light metals
- H01M 4/96: Carbon-based electrodes
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H01M 10/054: Accumulators with insertion or intercalation of metals other than lithium, e.g. with magnesium or aluminium
- H01M 12/08: composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
- H01M 4/625: {Carbon or graphite}
- H01M 10/06: Lead-acid accumulators (semi-lead accumulators H01M10/20)
- H01M 12/06: with one metallic and one gaseous electrode
- Y02E 60/10: Energy storage using batteries
- Y02E 60/13: Energy storage using capacitors
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10)
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

The present application is directed to methods for preparation of carbon materials. The carbon materials comprise enhanced electrochemical properties and find utility in any number of electrical devices, for example, as electrode material in ultracapacitors or batteries.

## Claims

### Claim 1

A battery anode electrode material comprising:
a plurality of composite particles comprising:
a plurality of porous carbon particles comprising a milled activated carbon particle; and
an electrochemical modifier incorporated into pores of the porous carbon particles,
wherein:
the porous carbon particles have a mean particle diameter of less than 1 mm;
the porous carbon particles have a specific surface area of at least 400 m2/g; and
the porous carbon particles have less than 500 ppm of all atoms having a molecular weight between 1 and 92, measured by photon induced x ray emissions.

### Claim 2 (depends on 1)

The material of claim 1, wherein the plurality of composite particles have a Dv50 of less than 1 mm and a span of 3 or less, wherein the span is defined as (Dv,90— Dv,10)/Dv,50 where Dv,10, Dv,50, and Dv,90 refer to pore sizes at 10%, 50%, and 90% respectively within a pore size distribution by volume of the plurality of composite particles.

### Claim 3 (depends on 1)

The material of claim 1, wherein each particle in the plurality of composite particles further comprises micropores and mesopores.

### Claim 4 (depends on 1)

The material of claim 1, wherein the electrochemical modifier is silicon.

### Claim 5 (depends on 1)

The material of claim 1, further comprising a carbon layer on the surface of the composite particles.

### Claim 6 (depends on 5)

The material of claim 5, wherein the carbon layer is between 1 nm and 50 nm thick.

### Claim 7 (depends on 5)

The material of claim 5, wherein the carbon layer is less than 5 nm in thickness.

### Claim 8 (depends on 1)

The material of claim 1, wherein the electrochemical modifier comprises between 0.5% and 99.5% by weight of the composite particles.

### Claim 9 (depends on 1)

The material of claim 1, wherein the porous carbon particles are spherical.

### Claim 10 (depends on 1)

A rechargeable lithium battery comprising:
(a) a positive electrode comprising a positive active material;
(b) a negative electrode comprising the electrode material of claim 1;
(c) an electrolyte solution; and
(d) a porous separator disposed between the positive electrode and the negative electrode.

### Claim 11

A battery anode electrode material comprising:
a plurality of composite particles comprising:
a plurality of porous carbon particles comprising a milled activated carbon particle; and
an electrochemical modifier comprising elemental silicon incorporated into pores of the porous carbon particles,
wherein:
the porous carbon particles have a mean particle diameter of less than 1 mm;
the porous carbon particles have a specific surface area of at least 400 m2/g; and
the porous carbon particles have less than 500 ppm of all atoms having a molecular weight between 1 and 92, measured by photon induced x ray emissions.

### Claim 12 (depends on 11)

The material of claim 11, wherein the plurality of composite particles have a Dv50 of less than 1 mm and a span of 3 or less, wherein the span is defined as (Dv,90— Dv,10)/Dv,50 where Dv,10, Dv,50, and Dv,90 refer to pore sizes at 10%, 50%, and 90% respectively within a pore size distribution by volume of the plurality of composite particles.

### Claim 13 (depends on 11)

The material of claim 11, wherein the porous carbon further comprises a total pore volume of at least 0.5 cc/g.

### Claim 14 (depends on 11)

The material of claim 11, wherein the porous carbon particles are electrically conductive.

### Claim 15 (depends on 11)

The material of claim 11, wherein the silicon carbon composite particle comprises a silicon content of 0.5% and 99.5% weight percent.

### Claim 16 (depends on 11)

The material of claim 11, wherein the silicon carbon composite particle comprises a silicon content of at least 25% to 95% weight percent.

### Claim 17 (depends on 11)

The material of claim 11, wherein the activated carbon further comprises at least 0.1 cc/g of pores with a pore size greater than 20 Angstroms.

### Claim 18 (depends on 11)

The material of claim 11, wherein the activated carbon further comprises a total of less than 500 ppm of all other elements, excluding the electrochemical modifier, having atomic numbers ranging from 1 to 92 as measured by proton induced x-ray emission.

### Claim 19 (depends on 11)

The material of claim 11, wherein the activated carbon comprises at least 0.2 cc/g of pores with a pore size less than 20 Angstroms.

### Claim 20 (depends on 11)

The material of claim 11, wherein the activated carbon comprises a peak pore volume range from 2 to 100 nm.

### Claim 21 (depends on 11)

The material of claim 11, wherein the porous carbon particles are spherical.

### Claim 22 (depends on 11)

A rechargeable lithium battery comprising:
a positive electrode comprising a positive active material;
a negative electrode comprising the electrode material of claim 11;
an electrolyte solution; and
a porous separator disposed between the positive electrode and the negative electrode.