# US 12,224,441 B2 · Nanostructured materials for battery > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,224,441 B2 - Document ID: US12224441B2 - Status: Granted - Kind: B2 - Application number: 17/192,204 - Filed: 2021-03-04 - Published: 2021-07-08 - Granted: 2025-02-11 - Earliest claimed: 2009-05-19 - Assignees: OneD Material, Inc. - Applicants: OneD Material, Inc. - Inventors: Yimin Zhu; Jay L Goldman; Jason Hartlove; Hans Jurgen Hofler - Web page: https://patentgrep.com/patent/US12224441B2 ## CPC - H01M 4/583: Carbonaceous material, e.g. graphite-intercalation compounds or CFx - H01M 4/134: Electrodes based on metals, Si or alloys - H01M 4/1395: of electrodes based on metals, Si or alloys - H01M 4/366: {as layered products} - H01M 4/62: Selection of inactive substances as ingredients for active masses, e.g. binders, fillers - H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries - Y02E 60/10: Energy storage using batteries - Y10T 29/49108: Electric battery cell making - 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 - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The present invention relates to nanostructured materials (including nanowires) for use in batteries. Exemplary materials include carbon-comprising, Si-based nanostructures, nanostructured materials disposed on carbon-based substrates, and nanostructures comprising nanoscale scaffolds. The present invention also provides methods of preparing battery electrodes, and batteries, using the nanostructured materials. ## Claims ### Claim 1 A battery anode electrode, comprising: (1) one or more Si-based nanostructures disposed on graphite powder, wherein the nanostructures have a core-shell structure and comprise any of (i) Si-based nanoparticles having all dimensions less than 50 nm, (ii) Si-based nanowires having a diameter of 20 nm to 100 nm and a length of 0.1 μm to 50 μm, or (iii) a combination thereof, wherein the nanostructures comprise lithium inserted in the nanostructures, wherein the graphite powder is in the form of separate particles having a diameter of 5 microns to 50 microns, and wherein the core of the nanostructures comprises crystalline silicon and the shell of the nanostructures comprises amorphous silicon; (2) a carbon-based material; and (3) a conductive polymer wherein the battery anode electrode comprises 5 weight % to 30 weight % of the nanostructures disposed on the graphite powder. ### Claim 2 A battery anode electrode, comprising: (1) one or more Si-based nanostructures disposed on graphite powder, wherein the nanostructures have a core-shell structure and comprise any of (i) Si-based nanoparticles having all dimensions less than 50 nm, (ii) Si-based nanowires having a diameter of 20 nm to 100 nm and a length of 0.1 μm to 50 μm, or (iii) a combination thereof, wherein the nanostructures comprise lithium inserted in the nanostructures, and wherein the graphite powder is in the form of separate particles having a diameter of 5 microns to 50 microns, wherein the core of the nanostructures comprises silicon and the shell of the nanostructures comprises carbon covalently bonded to the core of the nanostructures; (2) a carbon-based material; and (3) a conductive polymer, wherein the battery anode electrode comprises 5 weight % to 30 weight % of the nanostructures disposed on the graphite powder. ### Claim 3 (depends on 1) The battery anode electrode of claim 1, wherein the carbon-based material is selected from carbon black, graphite, graphene, graphene powder or graphite foil. ### Claim 4 (depends on 1) The battery anode electrode of claim 1, wherein the conductive polymer comprises any of PVDF, polypyrrole, polythiophene, polyethylene oxide, polyacrylonitrile, poly (ethylene succinate), polypropylene, poly (β-propiolactone), styrene butadiene rubber (SBR), carboxymethyl cellulose salt (CMC) and sulfonated fluoropolymers, polyimide, poly (acrylic acid), or combination thereof. ### Claim 5 (depends on 1) A battery comprising an anode electrode as claimed in claim 1, a cathode electrode and a separator. ### Claim 6 (depends on 5) The battery of claim 5, wherein the separator comprises a microporous polymer. ### Claim 7 (depends on 5) The battery of claim 5, wherein the separator comprises any of polypyrrole, polythiophene, polyethylene oxide, polyacrylonitrile, poly (ethylene succinate), polypropylene, poly (β-propiolactone), and sulfonated fluoropolymers, or combination thereof. ### Claim 8 (depends on 5) The battery of claim 5, wherein the battery further comprises an electrolyte comprising an alkali metal salt dissolved in organic solvent. ### Claim 9 (depends on 5) The battery of claim 5, wherein the battery further comprises an electrolyte comprising an alkali metal salt mixed with an ionically conducting polymer. ### Claim 10 (depends on 5) The battery of claim 5, wherein the battery further comprises an electrolyte comprising an alkali metal salt mixed with an ionically conducting inorganic material to form a suspension. ### Claim 11 A method of preparing a battery anode electrode, the method comprising: (a) mixing a plurality of Si-based nanostructures disposed on graphite powder with a conductive polymer and a carbon-based material to form a slurry, wherein the nanostructures have a core-shell structure and comprise any of (i) Si-based nanoparticles having all dimensions less than 50 nm, (ii) Si-based nanowires having a diameter of 20 nm to 100 nm and a length of 0.1 μm to 50 μm, or (iii) a combination thereof, wherein the nanostructures comprise lithium inserted in the nanostructures, wherein the graphite powder is in the form of separate particles having a diameter of 5 microns to 50 microns, and wherein the core of the nanostructures comprises crystalline silicon and the shell of the nanostructures comprises amorphous silicon; and (b) forming the slurry into the battery anode electrode; wherein the battery anode electrode comprises 5 weight % to 30 weight % of the nanostructures disposed on the graphite powder. ### Claim 12 (depends on 11) The method of claim 11, wherein the carbon-based material is selected from carbon black, graphite, graphene, graphene powder or graphite foil. ### Claim 13 (depends on 11) The method of claim 11, wherein the conductive polymer comprises any of PVDF, polypyrrole, polythiophene, polyethylene oxide, polyacrylonitrile, poly (ethylene succinate), polypropylene, poly (β-propiolactone), styrene butadiene rubber (SBR), carboxymethyl cellulose salt (CMC) and sulfonated fluoropolymers, polyimide, poly (acrylic acid), or combination thereof. ### Claim 14 A method of preparing a battery, the method comprising: (a) mixing a plurality of Si-based nanostructures disposed on graphite powder with a conductive polymer and a carbon-based material to form a slurry, wherein the nanostructures have a core-shell structure and comprise any of (i) Si-based nanoparticles having all dimensions less than 50 nm, (ii) Si-based nanowires having a diameter of 20 nm to 100 nm and a length of 0.1 μm to 50 μm, or (iii) a combination thereof, wherein the nanostructures comprise lithium inserted in the nanostructures, wherein the graphite powder is in the form of separate particles having a diameter of 5 microns to 50 microns, and wherein the core of the nanostructures comprises crystalline silicon and the shell of the nanostructures comprises amorphous silicon; (b) forming the slurry into the battery anode electrode; and (c) disposing a separator material between the anode electrode and a cathode electrode to form the battery, wherein the battery anode electrode comprises 5 weight % to 30 weight % of the nanostructures disposed on the graphite powder. ### Claim 15 (depends on 14) The method of claim 14, wherein the carbon-based material is selected from carbon black, graphite, graphene, graphene powder or graphite foil. ### Claim 16 (depends on 14) The method of claim 14, wherein the conductive polymer comprise any of PVDF, polypyrrole, polythiophene, polyethylene oxide, polyacrylonitrile, poly (ethylene succinate), polypropylene, poly (β-propiolactone), styrene butadiene rubber (SBR), carboxymethyl cellulose salt (CMC) and sulfonated fluoropolymers, polyimide, poly (acrylic acid), or combination thereof. ### Claim 17 (depends on 14) The method of claim 14, wherein the separator comprises a microporous polymer. ### Claim 18 (depends on 14) The method of claim 14, wherein the separator comprise any of polypyrrole, polythiophene, polyethylene oxide, polyacrylonitrile, poly (ethylene succinate), polypropylene, poly (β-propiolactone), and sulfonated fluoropolymers. ### Claim 19 (depends on 1) The battery anode electrode of claim 1, wherein the one or more Si-based nanostructures are attached to graphite powder. ### Claim 20 A method of preparing a battery anode electrode, the method comprising: (a) mixing a plurality of Si-based nanostructures disposed on graphite powder with a conductive polymer and a carbon-based material to form a slurry, wherein the nanostructures have a core-shell structure and comprise any of (i) Si-based nanoparticles having all dimensions less than 50 nm, (ii) Si-based nanowires having a diameter of 20 nm to 100 nm and a length of 0.1 μm to 50 μm, or (iii) a combination thereof, wherein the nanostructures comprise lithium inserted in the nanostructures, wherein the graphite powder is in the form of separate particles having a diameter of 5 microns to 50 microns, and wherein the core of the nanostructures comprises silicon and the shell of the nanostructures comprises carbon covalently bonded to the core of the nanostructures; and (b) forming the slurry into the battery anode electrode; wherein the battery anode electrode comprises 5 weight % to 30 weight % of the nanostructures disposed on the graphite powder. ### Claim 21 A method of preparing a battery, the method comprising: (a) mixing a plurality of Si-based nanostructures disposed on graphite powder with a conductive polymer and a carbon-based material to form a slurry, wherein the nanostructures have a core-shell structure and comprise any of (i) Si-based nanoparticles having all dimensions less than 50 nm, (ii) Si-based nanowires having a diameter of 20 nm to 100 nm and a length of 0.1 μm to 50 μm, or (iii) a combination thereof, wherein the nanostructures comprise lithium inserted in the nanostructures, wherein the graphite powder is in the form of separate particles having a diameter of 5 microns to 50 microns, and wherein the core of the nanostructures comprises silicon and the shell of the nanostructures comprises carbon covalently bonded to the core of the nanostructures; (b) forming the slurry into the battery anode electrode; and (c) disposing a separator material between the anode electrode and a cathode electrode to form the battery, wherein the battery anode electrode comprises 5 weight % to 30 weight % of the nanostructures disposed on the graphite powder.