WO2007083155A1 - A method of fabricating fibres composed of silicon or a silicon-based material and their use in lithium rechargeable batteries - Google Patents

A method of fabricating fibres composed of silicon or a silicon-based material and their use in lithium rechargeable batteries Download PDF

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Publication number
WO2007083155A1
WO2007083155A1 PCT/GB2007/000211 GB2007000211W WO2007083155A1 WO 2007083155 A1 WO2007083155 A1 WO 2007083155A1 GB 2007000211 W GB2007000211 W GB 2007000211W WO 2007083155 A1 WO2007083155 A1 WO 2007083155A1
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Prior art keywords
silicon
fibres
anode
cell
pillars
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Ceased
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PCT/GB2007/000211
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English (en)
French (fr)
Inventor
Mino Green
Feng-Ming Liu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nexeon Ltd
Ip2ipo Innovations Ltd
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Imperial Innovations Ltd
Nexeon Ltd
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First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=36010793&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2007083155(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority to MX2008009434A priority Critical patent/MX2008009434A/es
Priority to CA2636471A priority patent/CA2636471C/en
Priority to JP2008551861A priority patent/JP4839381B2/ja
Priority to US12/161,126 priority patent/US8101298B2/en
Priority to CN2007800029760A priority patent/CN101371381B/zh
Priority to BRPI0706946-4A priority patent/BRPI0706946A2/pt
Application filed by Imperial Innovations Ltd, Nexeon Ltd filed Critical Imperial Innovations Ltd
Priority to EP07704987A priority patent/EP1982370B1/en
Priority to HK08112620.5A priority patent/HK1118959B/en
Priority to EP12162277.3A priority patent/EP2472653B1/en
Publication of WO2007083155A1 publication Critical patent/WO2007083155A1/en
Priority to IL192940A priority patent/IL192940A0/en
Priority to NO20083260A priority patent/NO20083260L/no
Anticipated expiration legal-status Critical
Priority to US13/286,740 priority patent/US8597831B2/en
Priority to US14/055,371 priority patent/US9583762B2/en
Priority to US15/399,538 priority patent/US20170309900A1/en
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
    • H01M4/386—Silicon or alloys based on silicon
    • C—CHEMISTRY; METALLURGY
    • C30—CRYSTAL GROWTH
    • C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
    • C30B29/02—Elements
    • C30B29/06—Silicon
    • C—CHEMISTRY; METALLURGY
    • C30—CRYSTAL GROWTH
    • C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
    • C30B29/60—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape characterised by shape
    • C—CHEMISTRY; METALLURGY
    • C30—CRYSTAL GROWTH
    • C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B33/00—After-treatment of single crystals or homogeneous polycrystalline material with defined structure
    • C30B33/08—Etching
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/36—Accumulators not provided for in groups H01M10/05-H01M10/34
    • H01M10/38—Construction or manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/133—Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/134—Electrodes based on metals, Si or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1393—Processes of manufacture of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1395—Processes of manufacture of electrodes based on metals, Si or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
    • H01M4/583—Carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H01M4/587—Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
    • H01M2004/027—Negative electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/131—Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
    • H01M4/5825—Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making
    • Y10T29/49115—Electric battery cell making including coating or impregnating

Definitions

  • the invention relates to a method of fabricating fibres composed of silicon or a silicon-based material and their use the active anode material in rechargeable lithium battery cells.
  • silicon can be used as the active anode material of a rechargeable lithium-ion electrochemical cell (see, for example, Insertion Electrode Materials for Rechargeable Lithium Batteries, M. Winter, J. O. Besenhard, M. E. Spahr, and P.Novak in Adv. Mater. 1998, 10, No. 10).
  • the basic composition of a conventional lithium-ion rechargeable battery cell is shown in Fig. 1 including a graphite-based anode electrode, the component to be replaced by the silicon-based anode.
  • the battery cell includes a single cell but may also include more than one cell.
  • the battery cell generally comprises a copper current collector for the anode 10 and an aluminium current collector for the cathode 12 which are externally connectable to a load or to a recharging source as appropriate.
  • a graphite- based composite anode layer 14 overlays the current collector 10 and a lithium containing metal oxide-based composite cathode layer 16 overlays the current collector 12.
  • a porous plastic spacer or separator 20 is provided between the graphite-based composite anode layer 14 and the lithium containing metal oxide-based composite cathode layer 16 and a liquid electrolyte material is dispersed within porous plastic spacer or separator 20, the composite anode layer 14 and the composite cathode layer 16.
  • the porous plastic spacer or separator 20 may be replaced by a polymer electrolyte material and in such cases the polymer electrolyte material is present within both the composite anode layer 14 and the composite cathode layer 16.
  • the graphite being the electrochemically active material in the composite anode layer, has a maximum capacity of 372 mAh/g. It will be noted that the terms “anode” and “cathode” are used in the sense that the battery is placed across a load.
  • silicon when used as an active anode material in a lithium-ion rechargeable cell, provides a significantly higher capacity than the currently used graphite. Silicon when converted to the compound Li 21 Sis by reaction with lithium in an electrochemical cell, has a capacity of 4,200 mAh/g.
  • One approach uses silicon in the form of a powder, in some instances made into a composite with optionally an electronic additive and containing an appropriate binder such as polyvinylidene difluoride coated onto a copper current collector.
  • this electrode fails to show sustained capacity when subjected to charge/discharge cycles. It is believed that this capacity loss is due to partial mechanical isolation of the silicon powder mass arising from the volumetric expansion/contraction associated with lithium insertion/extraction into and from the host silicon. In turn this gives rise to agglomeration of the powder mass in electrically isolated "islands".
  • silicon is evaporated onto a roughened copper substrate to create medium-thickness films of up to 10 ⁇ m.
  • the silicon film breaks up to form pillars of silicon. These pillars can then reversibly react with lithium ions and good capacity retention is achieved.
  • the process does not function well with thicker film and the creation of the medium-thickness film is an expensive process.
  • the pillared structure caused by the break up of the film has no inherent porosity such that issues may arise with long term capacity retention.
  • the anode electrode structure uses fibres of silicon or silicon-based material, the problems of reversibly reacting these silicon or silicon-based fibres with lithium are overcome.
  • a composite structure that is a mixture of fibres a polymer binder and an electronic additive, the charge/discharge process becomes reversible and repeatable and good capacity retention is achieved.
  • the manner in which the fibres are laid can provide advantages.
  • the fibres may be deposited as a felt or felt- like structure. In the case of a composite structure this can be with the additional components, or the felt can be with a simple binder or, where structurally appropriate, loose.
  • a simplified method of fabricating fibres comprising etching a substrate to produce pillars and detaching the pillars providing a robust and high- yield approach.
  • Fig. 1 is a schematic diagram showing the components of a battery cell
  • Fig. 2 is a magnified photograph of an electrode according to the present invention
  • Fig.3 shows a first cycle voltage plot for a silicon f ⁇ bre/PVDF/Super P composite electrode.
  • the invention allows creation of fibres or hairs of silicon or silicon- based material and the use of these fibres to create both a composite anode structure with a polymer binder, an electronic additive (if required) and a metal foil current collector and a felt-like electrode structure.
  • the structure of the silicon elements that make up the composite overcomes the problem of charge/discharge capacity loss.
  • the fibres will have a length to diameter ratio of approximately 100: 1 and hence in an anode layer such as a composite anode layer, each fibre will contact other fibres many times along their length giving rise to a configuration where the chance of mechanical isolation arising from broken silicon contacts is negligible. Also, the insertion and removal of lithium into the fibres, although causing volume expansion and volume contraction, does not cause the fibres to be destroyed and hence the intra-fibre electronic conductivity is preserved.
  • the fibres may be manufactured by detaching pillars from a substrate.
  • the manner of fabrication of the pillars may be provided by a simple repeatable chemical process.
  • pillars can be made by dry etching, for example deep reactive ion etching of the type, for example, described in US application number 10/049736 which is commonly assigned herewith and incorporated herein by reference.
  • dry etching for example deep reactive ion etching of the type, for example, described in US application number 10/049736 which is commonly assigned herewith and incorporated herein by reference.
  • the skilled person will be familiar with the process such that detailed description is not required here. Briefly, however, a silicon substrate coated in native oxide is etched and washed so as to give a hydrophilic surface. Caesium chloride (CsCl) is evaporated on the surface and the coated substrate is transferred under dry conditions to a chamber of fixed water vapour pressure. A thin film of CsCl develops into an island array of hemispheres whose dimensional characteristics depend on initial thickness, water vapour pressure and time of development.
  • CsCl Caesium chloride
  • the island array provides an effective mask after which etching is carried out for example by reactive ion etching leaving an array of pillars corresponding to the hemispherical islands.
  • the CsCl resist layer is highly soluble in water and can be readily washed away.
  • the pillars can be made by wet etching/using a chemical galvanic exchange method for example as described in our co-pending application GB 0601318.9 with common assignees and entitled "Method of etching a silicon- based material", incorporated herewith by reference.
  • a related method which may also be used has been disclosed in Peng K-Q, Yan, Y-J Gao, S-P, Zhu J., Adv. Materials, 14 (2004), 1164-1167 ⁇ "Peng”); K. Peng et al, Angew. Chem. Int. Ed., 44 2737-2742; and K. Peng et al, Adv. Funct. Mater., 16 (2006), 387- 394.
  • pillars of for example 100 microns in length and 0.2 microns in diameter are fabricated on and from a silicon substrate. More generally pillars of length in the range of 20 to 300 microns and diameter or largest transverse dimension in the range of 0.08 to 0.5 microns may be used to provide the fibres.
  • the silicon substrate may be n- or p- type and, according to the chemical approach, and may be etched on any exposed (100) or (110) crystal face. Since the etching proceeds along crystal planes, the resulting fibres are single crystals.
  • the fibres will be substantially straight facilitating length to diameter ratio of approximately 100: 1 and, when in a composite anode layer, allowing each fibre to contact other fibres many times along their length.
  • the etching process can also be carried out either on very large scale integration (VLSI) electronic grade wafers or rejected samples of the same (single crystal wafers).
  • VLSI very large scale integration
  • photovoltaic grade polycrystalline material as used for solar panels, may also be used.
  • the substrate, with pillars attached is placed in a beaker or any appropriate container, covered in an inert liquid such as ethanol and subjected to ultra-sonic agitation. It is found that within several minutes the liquid is seen to be turbid and it can be seen by electron microscope examination that at this stage the pillars have been removed from their silicon base.
  • an inert liquid such as ethanol
  • n-type silicon material comprises etching the substrate in an HF solution in the presence of backside illumination of the silicon wafer.
  • the harvested silicon is filtered from solution and can be mixed with polyvinylidene difluoride and made into a slurry with a casting solvent such as n-methyl pyrrolidinone.
  • This slurry can then be applied or coated onto a metal plate or metal foil or other conducting substrate for example physically with a blade or in any other appropriate manner to yield a coated film of the required thickness and the casting solvent is then evaporated from this film using an appropriate drying system which may employ elevated temperatures in the range of 50 degrees C to 140 degrees C to leave the composite film free or substantially from casting solvent.
  • the resulting mat or composite film has a porous and/or felt-like structure in which the mass of silicon fibres is typically between 70 percent and 95 percent.
  • the composite film will have a percentage pore volume of 10-30 percent, preferably about 20 percent.
  • a felt or felt-like structure may be produced as a sheet material (not necessarily on a current collector) and act as its own current collector.
  • Fabrication of the lithium-ion battery cell thereafter can be carried out in any appropriate manner for example following the general structure shown in Fig. 1 but with a silicon or silicon based active anode material rather than a graphite active anode material.
  • a silicon or silicon based active anode material rather than a graphite active anode material.
  • the silicon fibres-based composite anode layer is covered by the porous spacer 18, the electrolyte added to the final structure saturating all the available pore volume.
  • the electrolyte addition is done after placing the electrodes in an appropriate casing and may include vacuum filling of the anode to ensure the pore volume is filled with the liquid electrolyte.
  • the coating was lightly rolled, and then electrode disks were cut out with a diameter of 12 mm. These were assembled into electrochemical cells in an argon filled glove box.
  • the counter electrode and reference electrode were both lithium metal.
  • the electrolyte was LiPF 6 in a mixture of organic carbonates.
  • the cell was tested on a VMP3 device. After a thirty minute soak, the cell was held at - 0.1 mA for one hour, and then at - 0.2 mA until the required lithiation capacity was achieved. The electrode was then delithiated at + 0.2 mA, up to a voltage of 1.0 V vs. LiZLi + .
  • Figure 3 shows the cell voltage during this first cycle.
  • a particular advantage of the approach described herein is that large sheets of silicon-based anode can be fabricated, rolled if necessary, and then slit or stamped out subsequently as is currently the case in graphite-based anodes for lithium-ion battery cells meaning that the approach described herein can be retrofitted with the existing manufacturing capability.
  • a further advantage of the arrangement described herein is that the structural strength in fact increases with each recharging operation. This is because the fibres are found to "weld" to one another as a result of the disrupted crystalline structure at the fibre junctions creating an amorphous structure. This in turn reduces the risk of capacity loss over multiple cycles as there is less risk of mechanical isolation of the fibres once the fibres become connected in the manner described above.
  • the pillar detaching operation can comprise any of a shaking, scraping, chemical or other operation as long as pillars are removed from the substrate to create fibres.
  • Reference to silicon-based material includes silicon where appropriate.
  • the fibres can have any appropriate dimension and can for example be pure silicon or doped silicon or other silicon-based material such as a silicon-germanium mixture or any other appropriate mixture.
  • the substrate from which pillars are created may be n- or p- type, ranging from 100 to 0.001 Ohm cm, or it may be a suitable alloy of silicon, for example Si x Ge 1-X .
  • the fibres can be used for any appropriate purpose such as fabrication of electrodes generally including cathodes.
  • the cathode material can be of any appropriate material, typically a lithium-based metal oxide or phosphate material such as LiCoO 2 , LiMn x Ni x Co 1-2X O 2 or LiFePO 4 .
  • the features of different embodiments can be interchanged or juxtaposed as appropriate and the method steps performed in any appropriate order.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Metallurgy (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Battery Electrode And Active Subsutance (AREA)
  • Secondary Cells (AREA)
  • Inorganic Fibers (AREA)
  • Silicon Compounds (AREA)
  • Cell Electrode Carriers And Collectors (AREA)
PCT/GB2007/000211 2006-01-23 2007-01-23 A method of fabricating fibres composed of silicon or a silicon-based material and their use in lithium rechargeable batteries Ceased WO2007083155A1 (en)

Priority Applications (14)

Application Number Priority Date Filing Date Title
EP12162277.3A EP2472653B1 (en) 2006-01-23 2007-01-23 Electrode structure comprising intersecting silicon-containing fibres for lithium rechargeable batteries
EP07704987A EP1982370B1 (en) 2006-01-23 2007-01-23 A method of fabricating a rechargeable lithium cell electrode comprising fibres of silicon or a silicon-based material
CA2636471A CA2636471C (en) 2006-01-23 2007-01-23 A method of fabricating fibres composed of silicon or a silicon-based material and their use in lithium rechargeable batteries
JP2008551861A JP4839381B2 (ja) 2006-01-23 2007-01-23 シリコン又はシリコンベースの物質で構成される繊維を製造する方法及びリチウム蓄電池におけるそれらの使用
US12/161,126 US8101298B2 (en) 2006-01-23 2007-01-23 Method of fabricating fibres composed of silicon or a silicon-based material and their use in lithium rechargeable batteries
CN2007800029760A CN101371381B (zh) 2006-01-23 2007-01-23 制造由硅或者基于硅的材料组成的纤维的方法及其在锂充电电池中的应用
BRPI0706946-4A BRPI0706946A2 (pt) 2006-01-23 2007-01-23 método de fabricação de fibras de silìcio ou de um material à base de silìcio, método de criação de um eletrodo de célula, método de fabricação de uma célula de lìtio recarregável, eletrodo compósito, célula eletroquìmica, ánodo de célula de lìtio recarregável, célula e dispositivo acionado por uma célula
MX2008009434A MX2008009434A (es) 2006-01-23 2007-01-23 Un metodo para fabricar fibras compuestas de silicio o un material a base de silicio y su uso en baterias de litio recargables.
HK08112620.5A HK1118959B (en) 2006-01-23 2007-01-23 A method of fabricating a rechargeable lithium cell electrode comprising fibres of silicon or a silicon-based material
IL192940A IL192940A0 (en) 2006-01-23 2008-07-21 A method of fabricating fibres composed of silicon or a silicon-based material and their use in lithium rechargeable batteries
NO20083260A NO20083260L (no) 2006-01-23 2008-07-23 Fremgangsmate for fremstilling av fibre inneholdende silisium eller et silisium-basert materiale og deres anvendelse i lithium oppladbare batterier
US13/286,740 US8597831B2 (en) 2006-01-23 2011-11-01 Method of fabricating fibres composed of silicon or a silicon-based material and their use in lithium rechargeable batteries
US14/055,371 US9583762B2 (en) 2006-01-23 2013-10-16 Method of fabricating fibres composed of silicon or a silicon-based material and their use in lithium rechargeable batteries
US15/399,538 US20170309900A1 (en) 2006-01-23 2017-01-05 Method of Fabricating Fibres Composed of Silicon or a Silicon-Based Material and Their Use in Lithium Rechargeable Batteries

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