Composite formed from semi-continuous and multi-step process

Abstract

A method and apparatus produce silicon-carbon composite materials through a chemical vapor deposition or a thermal disposition process in a fluidized bed reactor on a semi-continuous basis. The produced silicon-carbon composite has a unique structure that silicon particles are uniformly dispersed, bonded and embedded into the carbon conductive matrix and forming a secondary structure. The produced silicon-carbon composite can be used as advanced anode materials for lithium battery and other electrochemical energy storage device.

What is claimed is: 
     
         1 . A composite structure comprising:
 a plurality of graphene layers forming two or more gaps, wherein each gap is formed by a respective upper graphene layer and a respective lower graphene layer of the plurality of graphene layers; and   a plurality of silicon particles uniformly dispersed in at least one of the two or more gaps of graphene layers or on their surface, the plurality of silicon particles and plurality of graphene layers forming a graphene matrix, the plurality of silicon particles closely bonded and embedded within the graphene matrix,   wherein the graphene matrix embedded with silicon particles form blobs of coupled and conductive material agglomerates.   
     
     
         2 . The composite structure of  claim 1 , wherein the plurality of graphene layers and plurality of silicon particles form an embedded conductive matrix, of which there is a chemical bond force between silicon particles and the graphene matrix. 
     
     
         3 . The composite structure of  claim 1 , wherein the graphene matrix includes graphene and its derivatives or graphite and its derivatives. 
     
     
         4 . The composite structure of  claim 1 , wherein the silicon particles have a width between 2 nanometers and 2 microns. 
     
     
         5 . The composite structure of  claim 1 , wherein the silicon particles have a width between 10 nanometers and 1 micron. 
     
     
         6 . The composite structure of  claim 1 , wherein the composite structure includes silicon-graphene secondary agglomerated particles, the secondary agglomerated particles formed by rolling and agglomerating the silicon-graphene sheets into a ball to form a macro-structure. 
     
     
         7 . The composite structure of any one of  claim 1 , wherein the plurality of graphene layers with embedded silicon particles, and the secondary agglomerated particles are stable in a lithium battery environment, wherein the composite is usable for electrochemical energy storage devices. 
     
     
         8 . The composite structure of  claim 1 , wherein the plurality of graphene layers embedded with silicon particles are formed by a fluidized bed reactor. 
     
     
         9 . A composite structure comprising:
 a plurality of graphene layers forming two or more gaps, wherein each gap is formed by a respective upper graphene layer and a respective lower graphene layer of the plurality of graphene layers; and   a plurality of particles uniformly dispersed in at least one of the two or more gaps of graphene layers or on their surface, the plurality of particles and plurality of graphene layers forming a graphene matrix, the plurality of particles closely bonded and embedded within the graphene matrix, the particles including one or more of tin, lead, aluminum, gold, platinum, zinc, cadmium, silver, magnesium, and molybdenum,   wherein the graphene matrix embedded with particles form blobs of coupled and conductive material agglomerates.   
     
     
         10 . The composite structure of  claim 9 , wherein the plurality of graphene layers and plurality of silicon particles form an embedded conductive matrix, of which there is a chemical bond force between the particles and the graphene matrix. 
     
     
         11 . The composite structure of  claim 9 , wherein the particles have a width between 2 nanometers and 2 microns. 
     
     
         12 . The composite structure of  claim 9 , wherein the particles have a width between 10 nanometers and 1 micron. 
     
     
         13 . The composite structure of  claim 9 , wherein the graphene matrix includes graphene and its derivatives or graphite and its derivatives. 
     
     
         14 . The composite structure of  claim 9 , wherein the composite structure includes silicon-graphene secondary agglomerated particles, the secondary agglomerated particles formed by rolling and agglomerating the particle-graphene sheets into a ball to form a macro-structure.