Highly efficient manufacturing of silicon-carbon composites materials comprising ultra low z
AssigneeGroup14 Technologies, Inc.
InventorsHenry R. Costantino, Abirami Dhanabalan, Avery J. Sakshaug, Christopher Timmons, Rajankumar Patel
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Abstract
Silicon-carbon composite materials and related processes are disclosed that overcome the challenges for providing amorphous nano-sized silicon entrained within porous carbon. Compared to other, inferior materials and processes described in the prior art, the materials and processes disclosed herein find superior utility in various applications, including energy storage devices such as lithium ion batteries.
Claims31
1-20. (canceled)
A process for preparing silicon-carbon composite particles, the process comprising:
- a. providing a carbon scaffold comprising a pore volume, wherein the pore volume comprises greater than 70% microporosity;
- b. heating the porous carbon scaffold to a temperature from 300° C. to 500° C.;
- and
- c. contacting the carbon scaffold with a silane feedstock gas,
- wherein XSi of the process is greater than 50%, wherein XSi=100×(mol of silicon in the silicon-carbon composite)/(mol silane feedstock gas), wherein the mol silicon in the silicon-carbon composite is determined from the silicon content in the silicon-carbon composite by thermogravimetric analysis.
A process for preparing silicon-carbon composite particles, the process comprising:
- a. providing a carbon scaffold comprising a pore volume, wherein the pore volume comprises greater than 70% microporosity;
- b. heating the porous carbon scaffold to a temperature from 350° C. to 550° C.;
- and
- c. contacting the carbon scaffold with a silane feedstock gas;
- wherein:
- XSi of the process is greater than 60%, wherein XSi=100×(mol of silicon in the silicon-carbon composite)/(mol silane feedstock gas), wherein the mol silicon in the silicon-carbon composite is determined from the silicon content in the silicon-carbon composite by thermogravimetric analysis;
- and
- the silane gas comprises a recycle stream.
A process for preparing silicon-carbon composite particles, the process comprising:
- a. providing a carbon scaffold comprising a pore volume, wherein the pore volume comprises greater than 70% microporosity;
- b. heating the porous carbon scaffold to a temperature from 350° C. to 550° C.;
- and
- c. contacting the carbon scaffold with a silane feedstock gas,
- wherein:
- XSi of the process is greater than 70%, wherein XSi=100×(mol of silicon in the silicon-carbon composite)/(mol silane feedstock gas), wherein the mol silicon in the silicon-carbon composite is determined from the silicon content in the silicon-carbon composite by thermogravimetric analysis;
- and
- the silane gas comprises a recycle stream.
Dependencies are inferred from the claim text.