Solid electrolyte-secondary particle composites

Abstract

Composite anode-active particulates that include lithium-active, silicon nanoparticles in carbon matrices impregnated with solid electrolyte are described with methods for their preparation. The composite active particulates preferably include a solid electrolyte phase carried within pores of the particulate.

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         13 . A process for preparing a composite active particulate comprising:
 providing an active particulate that includes a porous heterogeneous matrix,
 the porous heterogeneous matrix including a carbon phase carrying and/or having embedded therein a plurality of silicon nanoparticles, and a plurality of pores therewithin; 
   providing a solution which includes a polysulfide, a solid-electrolyte particulate, and a solvent;   admixing the active particulate and the solution thereby allowing the solution to penetrate pores of the active particulate; and thereafter   removing the solvent.   
     
     
         14 . The process of  claim 13 , wherein the solid-electrolyte particulates have an average particle diameter of about 5 nm to about 250 nm. 
     
     
         15 . The process of  claim 13 , wherein the solid-electrolyte particulates have a formula of Li x M y S z  or Li x M y S z R n  where M includes B and/or P, where R is a halide, and where x, y, z, and n are positive integers. 
     
     
         16 . The process of  claim 13 , wherein the polysulfide includes a lithium polysulfide. 
     
     
         17 . The process of  claim 16 , wherein after removing the solvent from the admixture, the process further includes evaporating sulfur from the composite active particulate. 
     
     
         18 . The process of  claim 13 , wherein the solution includes about 1 wt. % to about 50 wt. % polysulfide and about 50 wt. % to about 99 wt. % solid-electrolyte particulate on a dry basis. 
     
     
         19 . The process of  claim 13 , wherein removing the solvent includes heating the admixture to a temperature from about 30° C. to about 300° C. 
     
     
         20 . A process for preparing an anode comprising:
 providing a plurality of active particulates that include a porous heterogeneous matrix, the porous heterogeneous matrix including a carbon phase carrying and/or having embedded therein a plurality of silicon nanoparticles, and a plurality of pores therewithin;   providing a solution which includes a polysulfide, a solid-electrolyte particulate, and a solvent;   admixing the active particulate and the solution thereby allowing the solution to penetrate pores of the active particulate; thereafter   coating a current collector with the admixture of the active particulate and the solution thereby forming a coating on the current collector; and then   removing the solvent from the coating on the current collector and thereby providing a composite laminate that includes composite active particulates in a solid-electrolytic continuous phase carried on the current collector,   wherein the composite active particulates include a solid-electrolytic phase carried within the pores of the porous heterogeneous matrix, and wherein the solid-electrolytic phase is covalently affixed to the solid-electrolytic continuous phase.