# US 12,006,400 B2 · Preparation of polymeric resins and carbon materials

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- Number: US 12,006,400 B2
- Document ID: US12006400B2
- Status: Granted
- Kind: B2
- Application number: 18/302,597
- Filed: 2023-04-18
- Published: 2023-11-02
- Granted: 2024-06-11
- 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/US12006400B2

## 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 electrode composition comprising a plurality of composite particles having an average particle size, Dv,50, of less than 1 mm and wherein individual composite particles comprise:
a. carbon material comprising:
i. a pore structure having micropores and mesopores,
ii. a maximum theoretical capacitance greater than 20 F/cm3 as measured at a current density of 0.5 Amp/g employing an electrolyte comprising tetraethylammonium tetrafluoroborane in acetonitrile,
iii. a specific surface area of at least 500 m2/g, and
iv. less than 500 ppm of all atoms having a molecular weight between 11 and 92, as measured by photon induced x-ray emissions; and
b. an electrochemical modifier incorporated within the pore structure of the carbon material, wherein the electrochemical modifier comprises elemental silicon.

### Claim 2 (depends on 1)

The carbon material of claim 1, wherein the specific surface area is between 1000 m2/g and 1500 m2/g.

### Claim 3 (depends on 1)

The carbon material of claim 1, wherein the maximum theoretical capacitance is greater than 23 F/cm3.

### Claim 4 (depends on 1)

The battery electrode composition of claim 1, wherein the electrochemical modifier comprises an elemental silicon content of at least 25% to 95% weight percent.

### Claim 5

A battery electrode composition comprising a plurality of composite particles having an average particle size, Dv,50, of less than 1 mm and wherein individual composite particles comprise:
a. carbon material comprising:
i. a pore structure having micropores and mesopores,
ii. a maximum theoretical capacitance greater than 20 F/cm3 as measured at a current density of 0.5 Amp/g employing an electrolyte comprising tetraethylammonium tetrafluoroborane in acetonitrile,
iii. a pore volume of at least 0.5 cm3/g, and
iv. less than 500 ppm of all atoms having a molecular weight between 11 and 92, as measured by photon induced x-ray emissions; and
b. an electrochemical modifier incorporated within the pore structure of the carbon material, wherein the electrochemical modifier comprises elemental silicon.

### Claim 6 (depends on 5)

The battery electrode composition of claim 5, wherein the maximum theoretical capacitance of the carbon material is greater than 23 F/cm3.

### Claim 7 (depends on 5)

The battery electrode composition of claim 5, wherein the carbon material is electrically conductive.

### Claim 8 (depends on 5)

The battery electrode composition of claim 5, wherein the electrochemical modifier comprises an elemental silicon content of at least 25% to 95% weight percent.

### Claim 9 (depends on 5)

The battery electrode composition of claim 5, wherein the carbon material is spherical.

### Claim 10

A battery electrode composition comprising a plurality of composite particles having an average particle size, Dv,50, of less than 1 mm and wherein individual composite particles comprise:
a. a carbon material comprising:
i. a pore volume totaling at least 0.5 cc/g, wherein the total pore volume comprises micropores and mesopores,
ii. a GM greater than or equal to 21, and
iii. less than 500 ppm of all atoms having a molecular weight between 11 and 92, as measured by photon induced x-ray emissions; and
b. an electrochemical modifier disposed within the pore volume of the carbon material, wherein the electrochemical modifier comprises elemental silicon,
wherein GM is measured as a ratio of a BET specific surface area of the carbon material and the pore volume of the carbon material multiplied by 100, such that the GM is calculated according to the equation below wherein the BET specific surface area is in units m2/g and the pore volume is in units cm3/g:
G
⁢
M
=
[
BET
⁢
Specific
⁢
Surface
⁢
Area
(
m
2
g
)
]
[
100
×
Pore
⁢
Volume
(
cm
3
g
)
]
.

### Claim 11 (depends on 10)

The composite particle of claim 10, wherein the carbon material has a tap density of at least 0.5 g/cc.

### Claim 12 (depends on 10)

The composite material of claim 10, wherein the carbon material has a span of 3 or less, wherein the span is defined as (Dv90−Dv10)/Dv50, and wherein Dv10, Dv50, and Dv90 refer to the pore size at 10%, 50%, and 90% of the distribution.

### Claim 13 (depends on 10)

The carbon material of claim 10, wherein the carbon material comprises less than 3 ppm of sulfur.

### Claim 14 (depends on 10)

The composite material of claim 10, wherein the carbon material comprises a pore volume totaling at least 0.7 cm3/g.

### Claim 15 (depends on 10)

The composite material of claim 10, wherein the carbon material further comprises a specific surface area of at least 500 m2/g.

### Claim 16 (depends on 10)

The composite material of claim 10, wherein the pore volume further comprise at least 0.1 cc/g of pores less than 20 angstroms.

### Claim 17 (depends on 10)

The composite material of claim 10, wherein the carbon material has a peak pore volume between 2 nm and 10 nm.

### Claim 18 (depends on 10)

The carbon composite of claim 10, wherein greater than 90% of the carbon material is substantially spherical.

### Claim 19 (depends on 10)

The carbon composite of claim 10, wherein greater than 95% of the carbon material is substantially spherical.

### Claim 20 (depends on 10)

The composite particle of claim 10, wherein the electrochemical modifier comprises an elemental silicon content of at least 25% to 95% weight percent.

### Claim 21 (depends on 10)

A battery comprising the composite particle of claim 10.