Anode active material, method of manufacturing the same, and lithium battery using the same

Abstract

Anode active materials, methods of producing the same and lithium batteries using the same are provided. More particularly, an anode active material having high capacity and excellent capacity retention, a method of producing the same and a lithium battery having a long lifespan using the same are provided. The anode active material comprises complex material particles comprising silicon and graphite, a carbon layer covering the surface of the complex material particles, and a silicon-metal alloy formed between the complex material particles and the amorphous carbon layer.

1. An anode active material comprising:
 a first material comprising a plurality of complex material particles comprising silicon and graphite; 
 a second material comprising a carbon layer covering at least a portion of a surface of the first material; and 
 a third material comprising a silicon-metal alloy, the third material being formed between the first material and the second material. 
 
     
     
       2. The anode active material of  claim 1 , wherein the weight ratio of silicon to graphite in the first material is about 2.0 or less. 
     
     
       3. The anode active material of  claim 1 , wherein the weight ratio of silicon to graphite in the first material is about 1.5 or less. 
     
     
       4. The anode active material of  claim 1 , wherein the weight ratio of silicon to graphite in the first material ranges from about 0.5 to about 1.4. 
     
     
       5. The anode active material of  claim 1 , wherein the molar ratio of metal to silicon in the silicon-metal alloy is about 0.01 or greater. 
     
     
       6. The anode active material of  claim 1 , wherein the molar ratio of metal to silicon in the silicon-metal alloy ranges from about 0.1 to about 0.5. 
     
     
       7. The anode active material of  claim 1 , wherein the carbon layer is an amorphous carbon layer. 
     
     
       8. The anode active material of  claim 1 , wherein the carbon layer is present in an amount ranging from about 1 to about 20 wt % based on the total weight of the anode active material. 
     
     
       9. The anode active material of  claim 1 , wherein the carbon layer is present in an amount ranging from about 3 to about 15 wt % based on the total weight of the anode active material. 
     
     
       10. The anode active material of  claim 1 , wherein the metal of the silicon-metal alloy is selected from the group consisting of nickel, cobalt, copper, zinc, aluminum and magnesium. 
     
     
       11. The anode active material of  claim 1 , wherein the silicon-metal alloy is a silicon-nickel alloy. 
     
     
       12. The anode active material of  claim 1 , wherein the carbon layer covers the entire surface of the first material. 
     
     
       13. A lithium battery comprising:
 a cathode; 
 an anode comprising the anode active material according to  claim 1 ; and 
 a separator. 
 
     
     
       14. A method of preparing an anode active material, the method comprising:
 providing a mixture of silicon particles and graphite particles and milling the mixture to form a milled mixture; 
 adding to the milled mixture a salt selected from the group consisting of long-chain metal carboxylate salts and long-chain metal sulfonate salts to form a second mixture; and 
 heat-treating the second mixture in an environment selected from the group consisting of a vacuum and an inert gas atmosphere. 
 
     
     
       15. The method of  claim 14 , wherein the salt comprises 20 or more carbon atoms and the metal is selected from the group consisting of nickel, cobalt, copper, zinc, aluminum and magnesium. 
     
     
       16. The method of  claim 14 , wherein the salt is selected from the group consisting of nickel stearate, nickel oleate, nickel palmitate, nickel linoleate, nickel laurate, nickel myristate, copper stearate, copper oleate, copper palmitate, copper linoleate, copper laurate and copper myristate. 
     
     
       17. The method of  claim 14 , wherein milling the mixture comprises high energy ball milling. 
     
     
       18. The method of  claim 14 , wherein the heat-treatment is performed at a temperature ranging from about 500 to about 1200° C. for a period of time ranging from about 0.5 to about 5 hours. 
     
     
       19. The method of  claim 14 , wherein an average particle diameter of the silicon particles ranges from about 0.05 to about 1 μm. 
     
     
       20. The method of  claim 14 , wherein an average particle diameter of the graphite particles ranges from about 1 to about 20 μm. 
     
     
       21. The lithium battery of claim 13, wherein the weight ratio of silicon to graphite in the first material is about 2.0 or less.  
     
     
       22. The lithium battery of claim 13, wherein the weight ratio of silicon to graphite in the first material is about 1.5 or less.  
     
     
       23. The lithium battery of claim 13, wherein the weight ratio of silicon to graphite in the first material ranges from about 0.5 to about 1.4.  
     
     
       24. The lithium battery of claim 13, wherein the molar ratio of metal to silicon in the silicon-metal alloy is about 0.01 or greater.  
     
     
       25. The lithium battery of claim 13, wherein the molar ratio of metal to silicon in the silicon-metal alloy ranges from about 0.1 to about 0.5.  
     
     
       26. The lithium battery of claim 13, wherein the carbon layer is an amorphous carbon layer.  
     
     
       27. The lithium battery of claim 13, wherein the carbon layer is present in an amount ranging from about 1 to about 20 wt % based on the total weight of the anode active material.  
     
     
       28. The lithium battery of claim 13, wherein the carbon layer is present in an amount ranging from about 3 to about 15 wt % based on the total weight of the anode active material.  
     
     
       29. The lithium battery of claim 13, wherein the metal of the silicon-metal alloy is selected from the group consisting of nickel, cobalt, copper, zinc, aluminum and magnesium.  
     
     
       30. The lithium battery of claim 13, wherein the silicon-metal alloy is a silicon-nickel alloy.  
     
     
       31. The lithium battery of claim 13, wherein the carbon layer covers the entire surface of the first material.  
     
     
       32. The lithium battery of claim 13, wherein the metal of the silicon-metal alloy is selected from the group consisting of Transition metals, Group II metals, and Group XIII metals.  
     
     
       33. The anode active material of claim 1, wherein the metal of the silicon-metal alloy is selected from the group consisting of Transition metals, Group II metals, and Group XIII metals.  
     
     
       34. An anode active material comprising:
 a first material comprising a plurality of complex material particles comprising silicon and graphite;   a second material comprising a carbon layer on at least a portion of a surface of the first material; and   a third material on at least a portion of the first material, the third material comprising a silicon-metal alloy.