High capacity, long cycle life battery anode materials, compositions and methods

A polymer derived ceramic (PDC) composition incorporating silicon at a molecular level to produce a battery anode powder material that increases capacity and life cycle of a battery, wherein the PDC composition comprises:

• a silicon hydride constituent, a vinyl-containing organic crosslinking additive, and a catalyst,
• wherein the silicon hydride constituent is selected from the group consisting of a silicon hydride monomer, a silicon hydride polymer and mixtures thereof,
• the silicon hydride monomer is selected from the group consisting of phenylsilane, diphenylsilane, methylphenylsilane, and methylphenylvinylsilane,
• the silicon hydride polymer is selected from the group consisting of tetramethylcyclotetrasiloxane, methylhydrogen siloxane, and co-polymers of dimethylsiloxane/methylhydrogen siloxane, phenylmethylsiloxane/methylhydrogen siloxane, or diphenylsiloxane/methylhydrogen siloxane,
• wherein the silicon hydride constituent is reacted with the vinyl containing organic crosslinking additive,
• the vinyl containing organic crosslinking additive consists of divinylbenzene,
• wherein approximately 100 weight percent of the composition comprises:
• approximately 35% to approximately 75% by weight of the silicon hydride monomer, silicon hydride polymer and mixtures thereof,
• approximately 4% to approximately 20% by weight of the divinylbenzene,
• approximately 0.1% to approximately 4% by weight of a catalyst,
• wherein the composition produces the battery anode powder material which increases capacity of a battery and increases First Cycle Efficiency (FCE) of a battery anode between approximately 73.81% to approximately 75.16%.

A polymer derived ceramic composition with a filler material incorporating silicon at a molecular level to produce a battery anode powder material that increases capacity of a battery and increases life cycle of a battery, wherein approximately 100 weight percent of the composition of the polymer with the filler material comprises:

• approximately 10% to approximately 90% by weight of silicon hydride monomer, silicon hydride polymer or mixtures thereof, the silicon hydride monomer is selected from the group consisting of phenylsilane, diphenylsilane, methylphenylsilane, and methylphenylvinylsilane, the silicon hydride polymer is selected from the group consisting of tetramethylcyclotetrasiloxane, methylhydrogen siloxane, and co-polymers of dimethylsiloxane/methylhydrogen siloxane, phenylmethylsiloxane/methylhydrogen siloxane, or diphenylsiloxane/methylhydrogen siloxane,
• approximately 10% to approximately 90% by weight of a graphite carbon material selected from the group consisting of synthetic graphite, natural graphite, purified graphite, bituminous coal, anthracite coal, sub-bituminous coal, lignite, peat and mixtures thereof,
• up to approximately 20% by weight of carbon nanotubes, graphite nanofibers, milled graphite fibers, carbon black or graphene materials;
• up to approximately 20% by weight of a filler selected from the group consisting of silicon micropowder or silicon nanopowder, titanium or titanium-based nanopowder, zirconium or zirconium based nanopowder, tin or tin-based nanopowder, copper or copper-based nanopowder, aluminum or aluminum based nanopowder, and lithium or lithium-based compound, and
• approximately 4% to approximately 20% of a crosslinking additive that consists of divinylbenzene,
• wherein the composition increases capacity of a battery and increases First Cycle Efficiency (FCE) of a battery anode between approximately 73.81% to approximately 75.16%.

A polymer derived ceramic (PDC) composition incorporating silicon at a molecular level to produce a battery anode powder material that increases the capacity of a battery and increases life cycle of a battery, wherein the PDC composition comprises:

• a silicon hydride constituent, a vinyl-containing organic modifier and a catalyst,
• wherein the silicon hydride constituent is selected from the groups consisting of a silicon hydride monomer, a silicon hydride polymer and mixtures thereof,
• the silicon hydride monomer is selected from the group consisting of phenylsilane, diphenylsilane, methylphenylsilane, and methylphenylvinylsilane,
• the silicon hydride polymer is selected from the group consisting of tetramethyleyclotetrasiloxane, methylhydrogen siloxane, and co-polymers of dimethylsiloxane/methylhydrogen siloxane, phenylmethylsiloxane/methylhydrogen siloxane, or diphenylsiloxane/methylhydrogen siloxane,
• wherein the silicon hydride constituent is reacted with the vinyl-containing organic modifier, wherein the vinyl-containing organic modifier consists of divinylbenzene and is between approximately 4% to approximately 20% by weight of the composition, wherein the composition increases capacity of a battery and increases First Cycle Efficiency (FCE) of a battery anode between approximately 73.81% to approximately 75.16%.

A polymer derived ceramic (PDC) composition incorporating silicon at a molecular level to produce a battery anode material that increases capacity of a battery and increases life cycle of a battery, wherein the PDC composition comprises:

• a silicon hydride constituent, a vinyl-containing organic modifier, and a catalyst,
• wherein the silicon hydride constituent is selected from the group consisting of a silicon hydride monomer, a silicon hydride polymer and mixtures thereof,
• the silicon hydride monomer is selected from the group consisting of phenylsilane, diphenylsilane, methylphenylsilane, and methylphenylvinylsilane,
• the silicon hydride polymer is selected from the group consisting of tetramethylcyclotetrasiloxane, methylhydrogen siloxane, and co-polymers of dimethylsiloxane/methylhydrogen siloxane, phenylmethylsiloxane/methylhydrogen siloxane, or diphenylsiloxane/methylhydrogen siloxane,
• wherein the silicon hydride constituent is reacted with vinyl-containing organic modifier,
• wherein the vinyl-containing organic modifier consists of divinylbenzene and is between approximately 4% to approximately 20% by weight of the composition,
• wherein the composition increases capacity of a battery and increases First Cycle Efficiency (FCE) of a battery anode between approximately 73.81% to approximately 75.16%.

A polymer derived ceramic composition with a filler material incorporating silicon at a molecular level to produce a battery anode powder material that increases capacity of a battery and increases life cycle of a battery, wherein approximately 100 weight percent of the composition comprises:

• approximately 10% to approximately 90% by weight of silicon hydride monomer, silicon hydride polymer or mixtures thereof,
• the silicon hydride monomer is selected from the group consisting of phenylsilane, diphenylsilane, methylphenylsilane, and methylphenylvinylsilane,
• the silicon hydride polymer is selected from the group consisting of tetramethylcyclotetrasiloxane, methylhydrogen siloxane, and co-polymers of dimethylsiloxane/methylhydrogen siloxane, phenylmethylsiloxane/methylhydrogen siloxane, or diphenylsiloxane/methylhydrogen siloxane,
• approximately 10% to approximately 90% by weight of a graphite carbon material selected from the group consisting of synthetic graphite, natural graphite, purified graphite, bituminous coal, anthracite coal, sub-bituminous coal, lignite, peat and mixtures thereof,
• up to approximately 20% by weight of carbon nanotubes, graphite nanofibers, milled graphite fibers, carbon black or graphene materials,
• up to approximately 20% by weight of the filler selected from the group consisting of silicon micropowder or silicon nanopowder, titanium or titanium-based nanopowder, zirconium or zirconium based nanopowder, tin or tin-based nanopowder;
• copper or copper-based nanopowder, aluminum or aluminum based nanopowder, and lithium or lithium-based compound, and
• approximately 4% to approximately 20% by weight of a crosslinking additive consists of divinylbenzene,
• wherein the composition increases capacity of a battery and increases First Cycle Efficiency (FCE) of a battery anode between approximately 73.81% to approximately 75.16%.

A battery anode composition comprising:

• a polymer derived ceramic (PDC) composition incorporating silicon at a molecular level, the polymer derived ceramic (PDC) composition comprises a silicon hydride constituent, vinyl-containing organic modifier, and a catalyst,
• wherein the silicon hydride constituent is selected from group consisting of a silicon hydride monomer, a silicon hydride polymer and mixtures thereof,
• the silicon hydride monomer is selected from the group consisting of phenylsilane, diphenylsilane, methylphenylsilane, and methylphenylvinylsilane,
• the silicon hydride polymer is selected from the group consisting of tetramethylcyclotetrasiloxane, methylhydrogen siloxane, and co-polymers of dimethylsiloxane/methylhydrogen siloxane, phenylmethylsiloxane/methylhydrogen siloxane, or diphenylsiloxane/methylhydrogen siloxane,
• wherein the silicon hydride constituent is reacted with the vinyl-containing organic modifier,
• the vinyl-containing modifier consists of divinylbenzene and is between approximately 4% to approximately 20% by weight of the composition, and
• wherein the composition increases capacity of a battery and increases First Cycle Efficiency (FCE) of a battery anode between approximately 73.81% to approximately 75.16%.