JP4104830B2 - Carbonaceous material, lithium secondary battery, and method for producing carbonaceous material - Google Patents

Carbonaceous material, lithium secondary battery, and method for producing carbonaceous material Download PDF

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JP4104830B2
JP4104830B2 JP2001058398A JP2001058398A JP4104830B2 JP 4104830 B2 JP4104830 B2 JP 4104830B2 JP 2001058398 A JP2001058398 A JP 2001058398A JP 2001058398 A JP2001058398 A JP 2001058398A JP 4104830 B2 JP4104830 B2 JP 4104830B2
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particles
phase
fine particles
carbonaceous material
secondary battery
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JP2002255530A (en
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恵子 松原
利章 津野
揆允 沈
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Samsung SDI Co Ltd
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Samsung SDI Co Ltd
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Priority to CNB021058458A priority patent/CN1220291C/en
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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
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • 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
    • 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
    • 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
    • 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

Description

【０００１】
【発明の属する技術分野】
本発明は、リチウム二次電池の負極活物質用の炭素質材料及びリチウム二次電池に関するものである。
【０００２】
【従来の技術】
小型軽量化及び高性能化が進んでいる携帯電子機器のニーズに応えるため、リチウム二次電池の高容量化が急務となっている。
ところで、リチウム二次電池の負極活物質の一つである黒鉛は、３７２ｍＡｈ／ｇの理論電気容量を有するが、これよりも高容量な負極活物質を得ようとするためには、非晶質炭素材料や、あるいは炭素材料に代わる新規材料の開発を進める必要がある。
黒鉛に代わる新規材料としては従来からケイ素やその化合物が検討されている。ケイ素やその化合物は、ケイ素自体がリチウムと合金を形成し、黒鉛よりも大きな電気容量が得られることが知られている。
そこで最近では、リチウム二次電池の負極材料として、（１）黒鉛にケイ素化合物の粉末を単に混合した材料や、（２）シランカップリング剤等を用いて黒鉛表面に微粉末のケイ素化合物等を化学的に固定した材料、（３）更に黒鉛系炭素質物とＳｉ等の金属質物とを非晶質な炭素質物で結合または被覆した材料が提案されている。
【０００３】
【発明が解決しようとする課題】
しかし、上記（１）の材料では、黒鉛とケイ素化合物とが必ずしも密着していないため、充放電サイクルの進行により黒鉛が膨張収縮した際に、ケイ素化合物が黒鉛から遊離してしまい、このケイ素化合物自体は電子伝導性が低いため、ケイ素化合物が負極活物質として十分に利用されなくなり、リチウム二次電池のサイクル特性が低下するという課題があった。
【０００４】
また上記（２）の材料では、充放電サイクルが初期のうちは黒鉛にケイ素化合物が密着した状態で保たれ、従ってケイ素化合物が黒鉛と同様に負極活物質として機能するが、充放電サイクルが進むと、リチウムとの合金形成に伴ってケイ素化合物自体が膨張し、これによってシランカップリング剤による結合を破壊してケイ素化合物が黒鉛から遊離し、ケイ素化合物が負極活物質として十分に利用されなくなり、リチウム二次電池のサイクル特性が低下するという課題があった。
また、負極材料の製造の際に施されるシランカップリング処理が均質に行われない場合があり、安定した品質の負極材料が容易に得られるまでには至っていないという課題があった。
【０００５】
更に上記（３）の材料でも上記（２）の材料と同様な問題が発生する。即ち、充放電サイクルが進むと、リチウムとの合金形成に伴う金属質物自体の膨張により、非晶質炭素質物による結合を破壊して金属質物が黒鉛系炭素質物から遊離し、金属質物が負極活物質として十分に利用されなくなり、リチウム二次電池のサイクル特性が低下するという課題があった。
【０００６】
本発明は、上記事情に鑑みてなされたものであって、充放電容量が高いと同時にサイクル特性に優れたリチウム二次電池の負極活物質用の炭素質材料を提供し、またこの炭素質材料を有するリチウム二次電池を提供することを目的とする。
【０００７】
【課題を解決するための手段】
上記の目的を達成するために、本発明は以下の構成を採用した。
本発明のリチウム二次電池の負極活物質用の炭素質材料は、Ｘ線広角回折による（００２）面の面間隔ｄ002が０．３３７nm未満である黒鉛粒子の周りに、珪素及び炭素を少なくとも含有するとともに前記黒鉛粒子より粒径が小さな複合粒子が分散して配置され、かつ前記黒鉛粒子及び前記複合粒子が０．３７ｎｍ以上の面間隔ｄ002を有する非晶質炭素膜によって被覆されてなり、前記複合粒子は、結晶質珪素からなるＳｉ微粒子の周りに導電性炭素材が配置されるとともに前記Ｓｉ微粒子及び前記導電性炭素材が硬質炭素膜により被覆されてなり、前記Ｓｉ微粒子は、結晶質Ｓｉ相中にＳｉＯ2相及びＳｉＣ相が析出したものであることを特徴とする。
【０００８】
なお本発明において、「周りに」の意義は、黒鉛粒子に対する複合粒子の位置関係を表すものであって、黒鉛粒子の「表面上もしくは表面近傍」を意味する。また、「周りに」の意義は、Ｓｉ微粒子に対する導電性炭素材の位置関係をも表すものであって、Ｓｉ微粒子の「表面上もしくは表面近傍」を意味する。
更に「分散して配置」の意義は、複数の複合粒子が凝集することなく相互に分散した状態で黒鉛粒子の表面に接合若しくは表面からわずかに離間して位置している状態を意味する。
また「被覆」の意義は、被覆対象粒子を完全に覆うことによって被覆対象粒子同士を結合させる状態を意味する。この場合、被覆対象粒子は必ずしも直接に接していなくても良い。
具体的には、黒鉛粒子及び複合粒子を非晶質炭素膜によって被覆するとは、黒鉛粒子及び複合粒子を非晶質炭素膜によって完全に覆って黒鉛粒子と複合粒子を結合させることや、非晶質炭素膜中に複合粒子を埋め込んで黒鉛粒子表面に近接させたことを意味する。
同様に、Ｓｉ微粒子及び導電性炭素材を硬質炭素膜によって被覆するとは、Ｓｉ微粒子及び導電性炭素材を硬質炭素膜によって完全に覆ってＳｉ微粒子と導電性炭素材を結合させることや、硬質炭素膜中に導電性炭素材を埋め込んでＳｉ微粒子表面に近接させたことを意味する。
更に、「析出」の意義は、結晶相の状態を説明する用語であり、母相中に母相と組成が異なる析出相が形成された状態を意味する。即ち、即ち、ＳｉＯ2相及びＳｉＣ相がＳｉ相中に一体不可分的に含まれた状態を意味するのであり、Ｓｉ相、ＳｉＯ2相、ＳｉＣ相が相互に物理的に分離した状態をいうものではない。
【０００９】
係る炭素質材料においては、黒鉛粒子及びＳｉ微粒子がＬｉを吸蔵するので、黒鉛粒子単独の場合よりも充放電容量が向上する。
また黒鉛粒子に対して高比抵抗なＳｉ微粒子の周りに導電性炭素材を配置することで、Ｓｉ微粒子の導電性を見かけ上、向上させる。
更にＳｉ微粒子を硬質炭素膜で被覆することにより、Ｌｉの吸蔵・放出に伴うＳｉ微粒子の体積膨張・収縮が機械的に抑えられる。
更にまた、黒鉛粒子と複合粒子を非晶質炭素膜で覆うことにより、黒鉛粒子が直接に電解液に触れることなく電解液分解が抑制されるとともに、複合粒子が黒鉛粒子から脱落することがなく、更に充電による体積膨張に起因するＳｉ微粒子の微粉化を防止する。
【００１０】
更に、結晶質Ｓｉ相中にＳｉＯ2相及びＳｉＣ相が析出することにより、相対的にＳｉ相の含有量が低減するとともに、Ｓｉ相に歪みを与えて結晶性を低下させ、過度のＬｉ吸蔵が抑制される。これにより、Ｌｉの吸蔵・放出によるＳｉ微粒子の膨張・収縮が適度に抑制される。ＳｉＯ2相及びＳｉＣ相はＬｉと反応しないためそれ自身は容量をもたないが、Ｌｉイオンの拡散を促進するとともに、Ｓｉ微粒子の体積膨張による微粉化が抑制される。
更に、ＳｉＯ2相とＳｉＣ相の両方を含むため、上記の機能をより効果的に得ることができる。
以上のことから、本発明の炭素質材料では、充放電容量を高くするとともに、Ｓｉ微粒子の体積膨張及び複合粒子の脱落、および充電による体積膨張に起因するＳｉ微粒子の微粉化を抑制して、サイクル特性の低下を防止することが可能になる。
特に、Ｓｉ微粒子の体積膨張による黒鉛粒子からの解離を防止してサイクル効率の低下をより効果的に防止することが可能になる。また、Ｌｉイオンの拡散速度が速まることにより、活物質が高密度に充填された電極においても素早いＬｉイオンの吸蔵・放出を行うことができ、充放電効率の向上が可能になる。
【００１１】
また本発明のリチウム二次電池の負極活物質用の炭素質材料は、先に記載の炭素質材料であって、Ｘ線広角回折による前記Ｓｉ相の（１１１）面の回折強度をＰＳｉとし、前記ＳｉＯ2相の（１１１）面の回折強度をＰＳｉＯ２とし、前記ＳｉＣ相の（１１１）面の回折強度をＰＳｉＣとしたとき、ＰＳｉＯ２／ＰＳｉが０．００５以上０．１以下、及び／または、ＰＳｉＣ／ＰＳｉが０．００５以上０．１以下であることを特徴とする。
【００１２】
係る炭素質材料においては、各相の回折強度比が上記の範囲であるため、Ｓｉ相の含有量が極端に低下することがなく、Ｌｉ吸蔵量が低下することがない。また、ＳｉＯ2相及びＳｉＣ相の含有量を最適化することにより、Ｓｉ微粒子の体積膨張・収縮を抑制する。
従って、炭素質材料の充放電容量を大きくし、更にＳｉ微粒子の体積膨張による黒鉛粒子からの解離、および充電による体積膨張に起因するＳｉ微粒子の微粉化を防いでサイクル効率の低下を防止することが可能になる。
【００１３】
また本発明のリチウム二次電池の負極活物質用の炭素質材料は、先に記載の炭素質材料であって、前記黒鉛粒子の粒径が２μｍ以上７０μｍ以下の範囲であり、前記複合粒子の粒径が５０ｎｍを越えて２μｍ以下の範囲であり、前記非晶質炭素膜の膜厚が５０ｎｍ以上５μｍ以下の範囲であることを特徴とする。
【００１４】
黒鉛粒子の粒径が２μｍ未満では、黒鉛粒子の粒径が複合粒子の粒径よりも相対的に小さくなり、複合粒子を黒鉛粒子の表面に均一に付着させることが困難になるので好ましくなく、粒径が７０μｍを越えると、集電体との密着性が低下するとともに、電極内の空隙も大きくなるので好ましくない。
また複合粒子の粒径を、５０ｎｍを越えて２μｍ以下、好ましくは５０ｎｍを越えて５００ｎｍ以下とするのは、黒鉛粒子の表面に複合粒子を分散配置させるために複合粒子の粒径を黒鉛粒子の最少粒径である２μｍ以下にする必要があるためであり、さらに粒径を５００ｎｍ以下とすれば膨張・収縮による複合粒子の体積変化を小さくできるからである。また粒径が５０ｎｍ以下では、複合粒子に含まれるＳｉ微粒子の結晶構造の乱れが大きくなって、Ｌｉ吸蔵量が低下するので好ましくない。
更に非晶質炭素膜の膜厚を５０ｎｍ未満にすると、黒鉛粒子が非晶質炭素膜によって完全に被覆されないおそれがあり、黒鉛粒子からの複合粒子の脱落を防止できなくなるとともに電解液分解を防止できなくなるおそれがあるので好ましくなく、膜厚が５μｍを越えると、リチウムイオンが黒鉛粒子まで到達せず、Ｌｉ吸蔵量が低下して充放電容量が低下するので好ましくない。
【００１５】
また本発明のリチウム二次電池の負極活物質用の炭素質材料は、先に記載の炭素質材料であって、前記Ｓｉ微粒子の粒径が１０ｎｍ以上２μｍ未満の範囲であり、前記導電性炭素材の比抵抗が１０-4Ω・ｍ以下であり、かつ前記硬質炭素膜の曲げ強度が５００ｋｇ／ｃｍ2以上であるとともに膜厚が１０ｎｍ以上１μｍ以下であることを特徴とする。
【００１６】
Ｓｉ微粒子の粒径を１０ｎｍ以上とするのは、Ｓｉ微粒子の結晶構造の乱れを防止してＬｉ吸蔵量を向上させるためであり、粒径を２μｍ未満とするのは、複合粒子の粒径を黒鉛粒子の最少粒径である２μｍより小さくするためである。
また、導電性炭素材の比抵抗を10-4Ω・ｍ以下とするのは、Ｓｉ微粒子に十分な導電性を付与するためである。
更に、硬質炭素膜の曲げ強度を５００ｋｇ／ｃｍ2以上とするのは、Ｌｉの吸蔵、放出に伴うＳｉ微粒子の膨張・収縮を機械的に抑えて体積変化を小さくするためであり、硬質炭素膜の膜厚を１０ｎｍ以上１μｍ以下とするのは、膜厚が１０ｎｍ未満であると導電性炭素材とＳｉ微粒子との結着力が低下するとともに複合粒子の体積膨張を抑制する効果がなくなって好ましくないためであり、膜厚が１μｍを越えると、リチウムイオンがＳｉ微粒子まで到達せず、充放電容量が低下してしまうので好ましくないためである。
【００１７】
また本発明のリチウム二次電池の負極活物質用の炭素質材料は、先に記載の炭素質材料であって、前記複合粒子の含有量が１重量％以上２５重量％以下であることを特徴とする。
【００１８】
複合粒子の含有量が１重量％未満では、炭素材料のみを活物質とした場合を上回る充分な放電容量を得ることができなくなるので好ましくない。
一方、含有量が２５重量％を越えると炭素材料部分の寄与が少なくなり、放電初期からＳｉの反応電位近くまで電圧が増加してしまうので好ましくなく、更に複合粒子間の距離が狭まって再凝集化し、Ｓｉ微粒子による体積膨張・収縮が起こりやすくなり、サイクル特性が低下するので好ましくない。
【００１９】
次に、本発明のリチウム二次電池は、先のいずれかに記載の炭素質材料を備えたことを特徴とする。係るリチウム二次電池は、例えば、正極と、電解質と、前記の負極材料（負極活物質）を有する負極を少なくとも有するもので、円筒形、角形、コイン型、あるいはシート型等の種々の形状からなる。尚、本発明のリチウム二次電池は、ここで挙げた形態に限られるものではなく、このほかの形態からなるものであってもよい。
係るリチウム二次電池によれば、エネルギー密度が高く、サイクル特性に優れたリチウム二次電池を構成することができる。
【００２０】
次に、本発明のリチウム二次電池の負極活物質用の炭素質材料の製造方法は、結晶質珪素からなるＳｉ微粒子を炭素るつぼ中で１３００℃以上１４００℃以下で焼成することにより、結晶質Ｓｉ相中にＳｉＯ２相及びＳｉＣ相を析出させる工程と、前記Ｓｉ微粒子に導電性炭素材を付着するとともに、該Ｓｉ微粒子を覆う高分子材料皮膜を形成して複合粒子前駆体とし、更に該複合粒子前駆体を焼成することにより前記高分子皮膜を硬質炭素膜として複合粒子を得る工程と、黒鉛粒子に前記複合粒子を付着するとともに、該黒鉛粒子を覆う高分子材料皮膜を形成して炭素質材料前駆体とし、更に該炭素質材料前駆体を焼成することにより前記高分子皮膜を０．３７ｎｍ以上の面間隔ｄ 002 を有する非晶質炭素膜として炭素質材料を得る工程とからなることを特徴とする。
【００２１】
【発明の実施の形態】
以下、本発明の実施の形態を図面を参照して説明する。
図１〜図４に、本発明のリチウム二次電池の負極活物質用の炭素質材料の断面模式図を示す。この炭素質材料は、黒鉛粒子の周りに複合粒子が分散して配置され、かつ黒鉛粒子と複合粒子とが非晶質炭素膜によって被覆されてなるものである。
【００２２】
ここで、「周りに」とは、黒鉛粒子に対する複合粒子の位置関係を表すものであって、黒鉛粒子の「表面上もしくは表面近傍」を意味する。即ち、複合粒子が黒鉛粒子の表面に接合した状態と、複合粒子が黒鉛粒子の表面から離間して黒鉛粒子の周囲に位置することを含む。
更に「分散して配置」とは、複数の複合粒子が相互に分散した状態で黒鉛粒子の表面に接合若しくは表面からわずかに離間して位置している状態を意味する。尚、複合粒子同士が凝集しない程度で相互に接触していてもよい。
また、「被覆」とは、被覆対象粒子を完全に覆うことによって被覆対象粒子同士を結合させる状態を意味する。この場合、被覆対象粒子は必ずしも直接に接していなくても良い。
具体的には、黒鉛粒子及び複合粒子を非晶質炭素膜によって被覆するとは、黒鉛粒子及び複合粒子を非晶質炭素膜によって完全に覆って黒鉛粒子と複合粒子を結合させることや、非晶質炭素膜中に複合粒子を埋め込んで黒鉛粒子表面に近接させたことを意味する。
従って本発明の炭素質材料には、以下に示すような様々な形態のものが含まれる。
【００２３】
例えば、図１に示す炭素質材料１は、黒鉛粒子２の表面に複数の複合粒子３…が相互に分散した状態で接合し、非晶質炭素膜４が複合粒子３…の粒径よりも小さくかつ均一な膜厚で黒鉛粒子２と複合粒子３…を被覆することにより構成されている。
【００２４】
また図２に示す炭素質材料１は、複数の黒鉛粒子２…の表面に複数の複合粒子３…が相互に分散した状態で接合し、非晶質炭素膜４が複合粒子３…の粒径よりも大きくかつ均一な膜厚で黒鉛粒子２と複合粒子３…を覆うように形成されるとととともに、この非晶質炭素膜４によって複数の黒鉛粒子２…が結合されて構成されている。
図２では、２つまたは３つの黒鉛粒子２…が非晶質炭素膜４によって結合されている状態を示すが、これに限られず、４つ以上の黒鉛粒子２…が非晶質炭素膜４によって結合されていても良い。
【００２５】
更に、図３に示す炭素質材料１は、黒鉛粒子２の表面に複数の複合粒子３…が相互に分散した状態で接合し、非晶質炭素膜４が黒鉛粒子２と複合粒子３…を被覆することにより構成されている。図３に示す非晶質炭素膜４の膜厚は不均一であり、例えば、黒鉛粒子２のみを覆う部分では複合粒子３…の粒径よりも大きく設定され、複合粒子３…を覆う部分では複合粒子３…の粒径よりも小さく設定されている。
【００２６】
更に、図４に示す炭素質材料１は、黒鉛粒子２の表面に複数の複合粒子３…が相互に分散した状態で接合し、非晶質炭素膜４が黒鉛粒子２と複合粒子３…を被覆することにより構成されている。図４に示す非晶質炭素膜４の膜厚は不均一であり、例えば、黒鉛粒子２のみを覆う部分では複合粒子３…の粒径よりも大きく設定され、複合粒子３…を覆う部分では複合粒子３…の粒径よりも小さく設定され、しかも非晶質炭素膜４の表面は複合粒子３…の形状を反映することなく凹凸のないなめらかな面に形成されている。
【００２７】
本発明の炭素質材料は図１〜４に示したものに限られず、上記の用語の意義を満足する限り、どのようなものであっても良い。
【００２８】
炭素質材料に含まれる黒鉛粒子１は、Ｘ線広角回折による（００２）面の面間隔ｄ002が０．３３５ｎｍ以上０．３３７ｎｍ未満とされたものを用いることが好ましく、０．３３５ｎｍ以上０．３４０ｎｍ以下のものがより好ましい。
面間隔ｄ002が０．３３７ｎｍ以上では黒鉛粒子の結晶性が低下し、初期不可逆容量が著しく増加するとともに、電子伝導性が低下するので好ましくない。
また、黒鉛粒子２の粒径は、２μｍ以上７０μｍ以下の範囲が好ましい。
黒鉛粒子２の粒径が２μｍ未満では、黒鉛粒子２の粒径が複合粒子３…の粒径よりも相対的に小さくなり、複合粒子３…を黒鉛粒子２の表面に均一に付着させることが困難になるので好ましくなく、粒径が７０μｍを越えると、集電体との密着性が低下するとともに、電極内の空隙も大きくなるので好ましくない。
【００２９】
次に非晶質炭素膜４は図１〜図４に示すように、黒鉛粒子２及び複合粒子３…を覆うとともに、複合粒子３…を黒鉛粒子２の表面上に付着させている。この非晶質炭素膜４は、図２に示すように黒鉛粒子２…同士を結合させる作用もある。
この非晶質炭素膜４は、熱可塑性樹脂、熱硬化性樹脂、ビニル系樹脂、セルロース系樹脂、フェノール系樹脂、石炭系ピッチ材料、石油系ピッチ材料、タール系材料等のうち少なくとも一種を熱処理して得られたもので、黒鉛化が比較的に進んでいないもので非晶質なものであり、０．３７ｎｍ以上の面間隔ｄ002を有するものである。非晶質炭素膜４が非晶質であるため、有機電解液が非晶質炭素膜４に触れても分解するおそれがなく、炭素質材料１の充放電効率を高くできる。
非晶質炭素膜４の面間隔ｄ002が０．３７ｎｍ未満であると、非晶質炭素膜４の結晶性が向上して黒鉛構造に近づき、有機電解液を分解させてしまうおそれがあるので好ましくない。
【００３０】
また、非晶質炭素膜４によって複合粒子３…を黒鉛粒子２の表面上に配置させているので、比較的高比抵抗な複合粒子３…が黒鉛粒子２から遊離するのを防止して、充放電反応に寄与しない複合粒子３…の発生を防止できる。
また、この非晶質炭素膜４は例えば、上記の熱可塑性樹脂、熱硬化性樹脂等を溶媒中に溶解するとともに更に黒鉛粒子２も投入し、黒鉛粒子２の表面に熱可塑性樹脂、熱硬化性樹脂等を析出させ、更に焼成して得られたものなので、黒鉛粒子２全体を完全に被覆させることが可能であり、また、密度が比較的低くリチウムイオンが透過しやすいので、黒鉛粒子２及び複合粒子３…とリチウムイオンとの反応を阻害することがない。
非晶質炭素膜４の膜厚は、５０ｎｍ以上５μｍ以下の範囲であることが好ましい。膜厚が５０ｎｍ未満では、黒鉛粒子２が完全に被覆されず、複合粒子３…が黒鉛粒子２から脱落するおそれがあるので好ましくなく、膜厚が５μｍを越えると、不可逆容量が増加するので好ましくない。
【００３１】
次に複合粒子３…は、図５に示すように、Ｓｉ微粒子５の周りに導電性炭素材６…が配置されるとともに、Ｓｉ微粒子５と導電性炭素材６…とが硬質炭素膜７によって被覆されてなるものである。
また、Ｓｉ微粒子３…は、結晶質Ｓｉ相中にＳｉＯ2相及びＳｉＣ相が析出したものである。
ここで、「周りに」とは、Ｓｉ微粒子５に対する導電性炭素材６…の位置関係を表すものであって、Ｓｉ微粒子５の「表面上もしくは表面近傍」を意味する。即ち、導電性炭素材６…がＳｉ微粒子５の表面に接合した状態と、導電性炭素材６…がＳｉ微粒子５の表面から離間してＳｉ微粒子５の周囲に位置することを含む。
また、Ｓｉ微粒子５と導電性炭素材６…とを硬質炭素膜７によって被覆するとは、Ｓｉ微粒子５及び導電性炭素材６…を硬質炭素膜７によって完全に覆ってＳｉ微粒子５と導電性炭素材６…を結合させることや、硬質炭素膜７中に導電性炭素材６…を埋め込んでＳｉ微粒子５表面に近接させたことを含む。
【００３２】
更に、「析出」とは、結晶相の状態を説明する用語であり、母相中に母相と組成が異なる析出相が形成された状態を意味する。即ち、ＳｉＯ2相及びＳｉＣ相がＳｉ相中に一体不可分的に含まれた状態を意味するのであり、Ｓｉ相、ＳｉＯ2相、ＳｉＣ相が相互に物理的に分離した状態をいうものではない。
【００３３】
複合粒子３の粒径は、５０ｎｍを越えて２μｍ以下の範囲が好ましく、５０ｎｍを越えて５００ｎｍ以下の範囲がより好ましい。
複合粒子３の粒径を２μｍ以下とするのは、黒鉛粒子２の表面に複合粒子３…を分散配置させるためには複合粒子３…の粒径を黒鉛粒子２の最少粒径である２μｍ以下にする必要があるためであり、更に粒径を５００ｎｍ以下とすればリチウムの吸蔵、放出に伴うＳｉ微粒子５の膨張・収縮による体積変化を小さくできるからである。また粒径の下限値を５０ｎｍを越えてとする理由は、５０ｎｍ以下であると複合粒子３に含まれるＳｉ微粒子５の結晶構造の乱れが大きくなり、Ｌｉ吸蔵量が低下して充放電容量が少なくなるおそれがあるためである。
【００３４】
Ｓｉ微粒子５は結晶質珪素（Ｓｉ相）を主体として含み、更にＳｉＯ2相及びＳｉＣ相が析出してなるものであり、粒径が１０ｎｍ以上２μｍ未満の範囲のものである。
珪素はリチウムと合金を形成する元素であり、この珪素からなるＳｉ相にリチウムイオンが作用することにより合金を形成する。特にリチウムイオンはＳｉ微粒子５の表面若しくはＳｉ微粒子５内部にある空隙部分に侵入して合金を形成し、これによりＳｉ微粒子５自体が膨張する。
【００３５】
また、このＳｉ微粒子５にはＳｉＯ2相及びＳｉＣ相が含まれており、これらの相はリチウムと反応しないためそれ自身は容量をもたないが、リチウムイオンの拡散を促進する作用がある。
従って、Ｓｉ相中にＳｉＯ2相及びＳｉＣ相が含まれると、Ｓｉ相中におけるリチウムイオンの拡散速度が向上し、例えばこの炭素質材料が高密度に充填された電極においても素早いＬｉイオンの吸蔵・放出を行うことができ、充放電効率を向上させることができる。
【００３６】
また、Ｓｉ微粒子５にＳｉＯ2相及びＳｉＣ相が含まれると、相対的にＳｉ相の含有量が低下し、またＳｉ相に歪みを与えて結晶性を低下させる。これによりリチウムイオンの吸蔵量が若干低下するが、同時にリチウムの吸蔵・放出に伴うＳｉ微粒子の膨張、収縮も適度に抑制される。これにより、Ｓｉ微粒子の体積膨張による微粉化が抑制されるとともに、Ｓｉ微粒子の体積膨張による複合粒子の脱落が少なくなり、サイクル特性の低下を防止できる。
【００３７】
具体的には、Ｘ線広角回折による前記Ｓｉ相の（１１１）面の回折強度をＰSiとし、前記ＳｉＯ2相の（１１１）面の回折強度をＰSiO2とし、前記ＳｉＣ相の（１１１）面の回折強度をＰSiCとしたとき、ＰSiO2／ＰSiが０．００５以上０．１以下、及び／または、ＰSiC／ＰSiが０．００５以上０．１以下であることが好ましい。
ＰSiO2／ＰSiが０．００５未満であると、ＳｉＯ2相の含有量が低下し、Ｓｉ微粒子５の膨張、収縮を抑制することができなくなり、またリチウムの拡散速度が低下するので好ましくない。ＰSiO2／ＰSiが０．１を越えると、Ｓｉ微粒子５中のＳｉ相の含有量が低下して充放電容量が低下してしまうので好ましくない。
また、ＰSiC／ＰSiが０．００５未満の場合も、ＳｉＣ相の含有量が低下し、Ｓｉ微粒子５の膨張、収縮を抑制することができなくなり、またリチウムの拡散速度が低下するので好ましくなく、ＰSiC／ＰSiが０．１を越えるとＳｉ微粒子５中のＳｉ相の含有量が低下して充放電容量が低下してしまうので好ましくない。
尚、ＳｉＯ2相及びＳｉＣ相は、それぞれ単独では上記のような効果を十分に発揮することができない。従って本発明においては、ＳｉＯ2相及びＳｉＣ相の両方を必ず含むことが好ましい。
【００３８】
尚、Ｓｉ微粒子５の粒径を１０ｎｍ以上とするのは、Ｓｉ微粒子５の結晶構造の乱れを防止してＬｉ吸蔵量を向上させるためであり、粒径を２μｍ未満とするのは、複合粒子３の粒径を黒鉛粒子２の最少粒径である２μｍより小さくする必要があるからである。
【００３９】
次に導電性炭素材６…は、Ｓｉ微粒子５の表面上または表面近傍に配置されてなるもので、図５ではＳｉ微粒子５の周りに粒子状の導電性炭素材６…が配置されているが、導電性炭素材６…の形状は粒子状に限られず、膜状、層状、繊維状等の様々な形態でもよい。
導電性炭素材６…は、半導体であるＳｉ微粒子５の表面に位置してＳｉ微粒子５に見かけ上の導電性を付与する。この導電性炭素材６…の比抵抗は１０-4Ω・ｍ以下の範囲が好ましい。比抵抗が１０-4Ω・ｍを越えると、Ｓｉ微粒子５の見かけ上の導電性が低下してＳｉ微粒子５に対するリチウムイオンの充放電反応が円滑に進行せず、炭素質材料の充放電容量を向上させることができなくなるので好ましくない。
導電性炭素材６…としては、例えば、カーボンブラック、ケッチェンブラック、気相成長炭素繊維(VGCF)等を例示できる。
【００４０】
硬質炭素膜７は、Ｓｉ微粒子５及び導電性炭素材６…を覆うとともに、導電性炭素材６…をＳｉ微粒子５の表面上に配置させている。この硬質炭素膜７は、ポリビニルアルコールやフェノール樹脂等を焼成して得られたもので、曲げ強度が５００ｋｇ／ｃｍ2以上であるとともに膜厚が１０ｎｍ以上１μｍ以下のものである。
【００４１】
硬質炭素膜７は、リチウムイオンの充放電反応に伴うＳｉ微粒子５の膨張、収縮に起因して生じる黒鉛粒子２からの複合粒子３の遊離を防止するためのもので、Ｓｉ微粒子５の膨張、収縮を機械的に抑制する。従って硬質炭素膜７の曲げ強度を５００ｋｇ／ｃｍ2以上にすることが好ましい。曲げ強度が５００ｋｇ／ｃｍ2未満であると、Ｓｉ微粒子５の膨張・収縮を機械的に抑えることができなくなり、複合粒子３が黒鉛粒子２から遊離するおそれがあるので好ましくない。
また、硬質炭素膜７の膜厚が１０ｎｍ未満であると、導電性炭素材６…とＳｉ微粒子５との結着力が低下するとともに複合粒子３の体積膨張を抑制する効果が低下して好ましくない。更に膜厚が１μｍを越えると、非晶質炭素に起因する不可逆容量の増加を招くため好ましくない。
【００４２】
そして、本発明の炭素質材料における上記の複合粒子３の含有量は、１重量％以上２５重量％以下であることが好ましい。複合粒子３の含有量が１重量％未満では、炭素材料のみを活物質とした場合を上回る充分な放電容量を得ることができないので好ましくない。また含有量が２５重量％を越えると炭素材料部分の寄与が少なくなり、放電初期からＳｉの反応電位に達してしまい、電池の平均電圧が低下するので好ましくなく、更に複合粒子３間の距離が狭まって再凝集化し、Ｓｉ微粒子５による体積膨張・収縮が起こりやすくなり、サイクル特性が低下するので好ましくない。
【００４３】
上記の炭素質材料１がリチウムイオンと反応する場合は、リチウムイオンが主として黒鉛粒子２に吸蔵されるとともにＳｉ微粒子５…と化合して合金を形成する。このＳｉ微粒子５…の表面には導電性炭素材６が付着していて導電性が見かけ上高くなっており、Ｓｉ微粒子５…に対してもリチウムイオンが容易に合金化する。
このとき、黒鉛粒子２及びＳｉ微粒子５…の体積が膨張するが、Ｓｉ微粒子５…は硬質炭素膜７により被覆されているので、体積膨張が機械的に抑制され、Ｓｉ微粒子５…を含む複合粒子３…が黒鉛粒子２から解離することがない。
また、Ｓｉ微粒子５…にはＳｉ相とＳｉＯ2相及びＳｉＣ相が含まれることから、リチウムイオンの吸蔵量が抑制されてＳｉ微粒子５…の体積膨張が適度に抑えられ、これによっても、Ｓｉ微粒子５…を含む複合粒子３…が黒鉛粒子２から解離することがない。
従って、Ｓｉ微粒子５…を常に充放電反応に寄与させることができ、充放電サイクルが進行しても炭素質材料１の充放電容量が低下することがない。
【００４４】
また、黒鉛粒子２と複合粒子３…を非晶質炭素膜４で覆うことにより、黒鉛粒子２が直接に有機電解液に触れることがなく、有機電解液の分解が抑制される。また、複合粒子３…が黒鉛粒子２から脱落することがなく、更に充電による体積膨張に起因するＳｉ微粒子５…の微粉化が防止される。
【００４５】
従って上記の炭素質材料１によれば、充放電容量を高くするとともに、Ｓｉ微粒子５…の体積膨張及び複合粒子３…の脱落、並びに充電に伴う体積膨張に起因するＳｉ微粒子５…の微粉化を抑制して、サイクル特性の低下を防止することができる。
【００４６】
上記の炭素質材料は、例えば、次のようにして製造することができる。
この炭素質材料の製造は、複合粒子を製造する工程と、得られた複合粒子に黒鉛粒子を混合し、これらを非晶質炭素膜で被覆する工程とからなる。
まず、複合粒子を製造する工程では、Ｓｉ相のみからなるＳｉ微粒子を用意し、このＳｉ微粒子を炭素製るつぼに投入して不活性雰囲気中で１３００〜１４００℃程度で１２０〜３００分間加熱する。この加熱により、るつぼの構成材料である炭素とＳｉ相が反応してＳｉ微粒子中にＳｉＣ相が析出するとともに、僅かに混入した酸素とＳｉ相が反応してＳｉ微粒子中にＳｉＯ2相が析出する。
ただし、加熱温度が１３００℃未満及び／または加熱時間が１２０分未満であると、ＳｉＣ相及びＳｉＯ2相が十分に析出しないので好ましくなく、加熱温度が１４００℃を越えるとＳｉが溶融するため好ましくなく、加熱時間が３００分を越えると、ＳｉＣ相及びＳｉＯ2相の析出量が過大になるので好ましくない。
【００４７】
次に、加熱後のＳｉ微粒子と導電性炭素材とを、乾式混合あるいは湿式混合により混合する。湿式混合の場合、イソプロピルアルコール、アセトン、エタノール、水等の分散媒を用いることが好ましい。
【００４８】
次に、高分子材料を適当な溶媒に溶解し、この溶液にＳｉ微粒子と導電性炭素材の混合物を混合した後、溶媒を除去する。溶媒を除去することにより、Ｓｉ微粒子及び導電性炭素材に高分子膜を被覆した複合粒子前駆体が形成される。
なお、上記の高分子材料は、熱可塑性樹脂、熱硬化性樹脂、ビニル系樹脂、セルロース系樹脂、フェノール系樹脂のうち少なくとも一種を用いることが好ましく、特にフェノール樹脂を用いることが好ましい。また石炭系ピッチ材料、石油系ピッチ材料、タール系材料等を用いても良い。
【００４９】
次に、複合粒子前駆体を熱処理することにより、高分子膜を炭化させて硬質炭素膜を形成する。
熱処理は、真空雰囲気中または不活性ガス雰囲気中で行うことが好ましく、熱処理温度は８００℃以上１２００℃以下の範囲が好ましく、熱処理時間は１２０分以上行うことが好ましい。
熱処理を真空雰囲気または不活性ガス雰囲気で行うと、高分子膜の酸化が防止されて良好な硬質炭素膜が形成できる。
尚、熱処理温度が８００℃未満だと炭化が完全に行われず、硬質炭素膜の比抵抗が高く、リチウムイオンの挿入・脱理が行われにくくなり好ましくなく、熱処理温度が１２００℃を越えると、Ｓｉ微粒子が炭化されてＳｉＣが過剰に生成してしまうので好ましくない。
同様に、熱処理時間が１２０分未満だと均一な硬質炭素膜が形成できないので好ましくない。
このようにして、複合粒子が得られる。
【００５０】
次の工程では、得られた複合粒子に、乾式混合あるいは湿式混合により黒鉛粒子を混合する。湿式混合の場合、イソプロピルアルコール、アセトン、エタノール、水等の分散媒を用いることが好ましい。
【００５１】
次に、別の高分子材料を適当な溶媒に溶解し、この溶液に複合粒子及び黒鉛粒子の混合物を混合した後、溶媒を除去する。溶媒を除去することにより、複合粒子及び黒鉛粒子に高分子膜を被覆した炭素質材料前駆体が形成される。
なお、上記の高分子材料は、熱可塑性樹脂、熱硬化性樹脂、ビニル系樹脂、セルロース系樹脂、フェノール系樹脂等のうち少なくとも一種を用いることが好ましく、特にフェノール樹脂を用いることが好ましい。また石炭系ピッチ材料、石油系ピッチ材料、タール系材料等を用いてもよい。
【００５２】
次に、炭素質材料前駆体を熱処理することにより、高分子膜を炭化させて０．３７ｎｍ以上の面間隔ｄ 002 を有する非晶質炭素膜を形成する。
熱処理は、真空雰囲気中または不活性ガス雰囲気中で行うことが好ましく、熱処理温度は８００℃以上１２００℃以下の範囲が好ましく、熱処理時間は１２０分以上行うことが好ましい。
熱処理を真空雰囲気または不活性ガス雰囲気で行うと、高分子膜の酸化が防止されて良好な非晶質炭素膜が形成できる。
尚、熱処理温度が８００℃未満だと温度が低いために炭化が完全に行われず、非晶質炭素膜の比抵抗が高く、リチウムイオンの挿入・脱理が行われにくくなり好ましくなく、熱処理温度が１２００℃を越えるとＳｉ微粒子が炭化されてＳｉＣが過剰に生成するとともに、高分子膜の黒鉛化が進行し、非晶質炭素膜の強度が低下するので好ましくない。
同様に、熱処理時間が１２０分未満だと均一な硬質炭素膜が形成できないので好ましくない。
このようにして、本発明に係る炭素質材料が得られる。
【００５３】
上記の炭素質材料を有する負極と、リチウムの吸蔵・放出が可能な正極及び有機電解質とにより、リチウム二次電池を構成することができる。
正極としては、例えば、ＬｉＭｎ2Ｏ4、ＬｉＣｏＯ2、ＬｉＮｉＯ2、ＬｉＦｅＯ2、Ｖ2Ｏ5、ＴｉＳ、ＭｏＳ等のリチウムの吸蔵、放出が可能な正極材料や、有機ジスルフィド化合物または有機ポリスルフィド化合物等の正極材料を含むものが例示できる。
正極または負極の具体例として、上記の正極材料または炭素質材料に、結着材と更に必要に応じて導電助材を混合し、これらを金属箔若しくは金属網からなる集電体に塗布してシート状に成形したものを例示できる。
【００５４】
有機電解質としては、例えば、非プロトン性溶媒にリチウム塩が溶解されてなる有機電解液を例示できる。
非プロトン性溶媒としては、プロピレンカーボネート、エチレンカーボネート、ブチレンカーボネート、ベンゾニトリル、アセトニトリル、テトラヒドロフラン、２−メチルテトラヒドロフラン、γ−ブチロラクトン、ジオキソラン、４−メチルジオキソラン、Ｎ、Ｎ−ジメチルホルムアミド、ジメチルアセトアミド、ジメチルスルホキシド、ジオキサン、１，２−ジメトキシエタン、スルホラン、ジクロロエタン、クロロベンゼン、ニトロベンゼン、ジメチルカーボネート、メチルエチルカーボネート、ジエチルカーボネート、メチルプロピルカーボネート、メチルイソプロピルカーボネート、エチルブチルカーボネート、ジプロピルカーボネート、ジイソプロピルカーボネート、ジブチルカーボネート、ジエチレングリコール、ジメチルエーテル等の非プロトン性溶媒、あるいはこれらの溶媒のうちの二種以上を混合した混合溶媒を例示でき、特にプロピレンカーボネート、エチレンカーボネート、ブチレンカーボネートのいずれか１つを必ず含むとともにジメチルカーボネート、メチルエチルカーボネート、ジエチルカーボネートのいずれか１つを必ず含むことが好ましい。
【００５５】
また、リチウム塩としては、ＬｉＰＦ6、ＬｉＢＦ4、ＬｉＳｂＦ6、ＬｉＡｓＦ6、ＬｉＣｌＯ4、ＬｉＣＦ3ＳＯ3、Ｌｉ（ＣＦ3ＳＯ2）2Ｎ、ＬｉＣ4Ｆ9ＳＯ3、ＬｉＳｂＦ6、ＬｉＡlＯ4、ＬｉＡlＣl4、ＬｉＮ（ＣxＦ2x+1ＳＯ2）（ＣyＦ2y 十 1ＳＯ2）（ただしｘ、ｙは自然数）、ＬｉＣｌ、ＬｉＩ等のうちの１種または２種以上のリチウム塩を混合させてなるものを例示でき、特にＬｉＰＦ6、ＬｉＢＦ4のいずれか１つを含むものが好ましい。
またこの他に、リチウム二次電池の有機電解液として従来から知られているものを用いることもできる。
【００５６】
また有機電解質の別の例として、ＰＥＯ、ＰＶＡ等のポリマーに上記記載のリチウム塩のいずれかを混合させたものや、膨潤性の高いポリマーに有機電解液を含浸させたもの等、いわゆるポリマー電解質を用いても良い。
更に、本発明のリチウム二次電池は、正極、負極、電解質のみに限られず、必要に応じて他の部材等を備えていても良く、例えば正極と負極を隔離するセパレータを具備しても良い。
【００５７】
上記のリチウム二次電池によれば、上記の炭素質材料１を備えているので、エネルギー密度が高く、サイクル特性に優れたリチウム二次電池を構成することができる。
【００５８】
【実施例】
［実験例１の炭素質材料の製造］
平均粒径０．９μｍのＳｉ微粒子１５ｇを、内容積２００ｍｌの炭素製るつぼに入れ、アルゴンガス雰囲気中で１４００℃で２４０分間加熱した。
次に、加熱後のＳｉ微粒子２重量部に、１重量部のカーボンブラックを混合した。なお、カーボンブラックは比抵抗が１０-4Ω・ｍ以下のものであった。
次に１０重量部のフェノール樹脂をイソプロピルアルコールに溶解させた溶液を用意し、この溶液に、先程のＳｉ微粒子及びカーボンブラックの混合物を混合し、十分に攪拌した後、溶媒を除去した。このようにして、Ｓｉ微粒子の表面にカーボンブラックとフェノール樹脂被膜とが付着してなる複合粒子前駆体を形成した。
次に、この複合粒子前駆体をアルゴンガス雰囲気中、１０００℃で１８０分間熱処理することにより、フェノール樹脂皮膜を炭化して厚さ０．０５μｍの硬質炭素膜を形成した。
尚、上記と同じ条件でフェノール樹脂を単独で炭化させた場合、得られる炭化物の曲げ強度は８００ｋｇ／ｃｍ2程度であることから、上記の硬質炭素膜の曲げ強度も同程度であると推定される。
このようにして複合粒子を得た。
【００５９】
次に、平均粒径１５μｍの天然黒鉛の９５重量部に、５重量部の上記複合粒子を添加し、更にイソプロピルアルコールを加えて湿式混合した。尚、天然黒鉛のＸ線広角回折による（００２）面の面間隔ｄ002は０．３３５５ｎｍであった。
次に、上記の天然黒鉛と複合粒子の混合物に、１０重量部のフェノール樹脂を含むイソプロピルアルコール溶液を添加して混合した後に、イソプロピルアルコールを蒸発させた。このようにして、天然黒鉛の表面に複合粒子とフェノール樹脂皮膜とが付着してなる炭素質材料前駆体を形成した。
【００６０】
次に、この炭素質材料前駆体を、真空雰囲気中、１０００℃（１２７３Ｋ）で焼成することにより、フェノール樹脂を炭化させて厚さ０．０５μｍの非晶質炭素膜とした。
尚、上記と同じ条件でフェノール樹脂を単独で炭化させた場合、得られる炭化物の（００２）面の面間隔ｄ002が０．３９ｎｍ程度であることから、上記の非晶質炭素膜の面間隔ｄ002も同程度であると推定される。
このようにして実験例１の炭素質材料を得た。
【００６１】
［実験例２の炭素質材料の製造］
平均粒径２．０μｍのＳｉ微粒子を用いたこと以外は実験例１と全く同様の方法で、複合粒子および炭素質材料を得た。
【００６２】
［実験例３の炭素質材料の製造］
また、複合粒子に代えて粒径０．９μｍのＳｉ微粒子の５重量部を、９５重量部の天然黒鉛に混合し、フェノール樹脂膜を形成して焼成したこと以外は上記と同様にして、実験例３の炭素質材料を得た。
【００６３】
［充放電試験用のテストセルの作成］
上記の実験例１〜２の炭素質材料に、ポリフッ化ビニリデンを混合し、更にＮ−メチルピロリドンを加えてスラリー液とした。このスラリー液を、ドクターブレード法により厚さ１４μｍの銅箔に塗布し、真空雰囲気中で１２０℃、２４時間乾燥させてＮ−メチルピロリドンを揮発させた。このようにして、厚さ１００μｍの負極合材を銅箔上に積層した。なお、負極合材中のポリフッ化ビニリデンの含有量は８重量％であり、負極合材の密度は１．５ｇ／ｃｍ3以上であった。
そして、負極合材を積層させた銅箔を直径１３ｍｍの円形に打ち抜いて実験例１〜２の負極電極とした。
【００６４】
また、上記の実験例３の炭素質材料にポリフッ化ビニリデンとＮ−メチルピロリドンを加え、さらにカーボンブラックを添加してスラリー液としたこと以外は、上記と同様にして実験例３の負極電極を得た。尚、負極合材中のポリフッ化ビニリデンの含有量は８重量％であり、カーボンブラックの含有量は２．５重量％であった。
【００６５】
実験例１〜２及び実験例３の負極電極を作用極とし、円形に打ち抜いた金属リチウム箔を対極とし、作用極と対極との間に多孔質ポリプロピレンフィルムからなるセパレータを挿入し、電解液としてジメチルカーボネート（ＤＭＣ）、ジエチルカーボネート（ＤＥＣ）及びエチレンカーボネート（ＥＣ）の混合溶媒に溶質としてＬｉＰＦ６が１（モル／Ｌ）の濃度となるように溶解させたものを用いて、コイン型のテストセルを作成した。
そして、充放電電流密度を０．２Ｃとし、充電終止電圧を０Ｖ（Ｌ ｉ／Ｌ ｉ+）、放電終止電圧を１．５Ｖ（Ｌ ｉ／ Ｌｉ+）として充放電試験を行った。
【００６６】
表１に、１サイクル目における放電容量及び充放電効率を示す。また、２サイクル目の放電容量を１サイクル目の放電容量で除した容量比（2nd/1st）を求めた。結果を表１に併せて示す。
【００６７】
【表１】

Figure 0004104830
【００６８】
表１に示すように、１サイクル目の放電容量は、実験例３よりも実験例１の方が低くなっていることがわかる。
これは、Ｓｉ微粒子を炭素製るつぼ中で加熱したことにより、Ｓｉ微粒子のＳｉ相中にＳｉＣ相及びＳｉＯ2相が析出し、リチウムと合金を形成するＳｉ相の含有量が相対的に減少したためと考えられる。
図６には、加熱後のＳｉ微粒子のＸ線回折パターンを示す。図６から明らかなように、Ｓｉ相の他に、ＳｉＣ相及びＳｉＯ2相に由来する回折ピークが観察される。Ｓｉ相の（１１１）面の回折強度をＰSiとし、ＳｉＯ2相の（１１１）面の回折強度をＰSiO2とし、ＳｉＣ相の（１１１）面の回折強度をＰSiCとしたとき、図６から、ＰSiO2／ＰSi＝０．０１０であり、ＰSiC／ＰSi＝０．０４２であることがわかる。
【００６９】
次に、１サイクル目における充放電効率は、実験例１が９０％に達しているのに対し、比較例では８３％にとどまっている。
また容量比（2nd/1st）については、実験例１が９８％近くに達しているのに対し、実験例３は９２％程度にとどまっている。
これは、Ｓｉ微粒子中にＳｉＣ相及びＳｉＯ2相が析出し、リチウムと合金を形成するＳｉ相の含有量が相対的に減少したために、Ｓｉ微粒子自体の膨張、収縮が適度に抑制され、これにより複合粒子の黒鉛からの遊離が少なくなって、サイクル特性が向上したためと考えられる。
また、実験例１，２の結果を比較すると、Ｓｉ微粒子の平均粒径が２．０μｍである実験例２のほうが初回充放電効率、および容量比（2nd/1st）とも実験例１を下回っている。これはＳｉの粒径が２．０μｍ程度以上になると、充電によるＳｉの膨脹が大きく、焼成によって析出させたＳｉＣ相及びＳｉＯ2相の効果だけではＳｉの微粉化および極板からの脱落を抑制できないためと考えられる。
【００７０】
【発明の効果】
以上、詳細に説明したように、本発明の炭素質材料によれば、黒鉛粒子及びＳｉ微粒子がＬｉを吸蔵するので、黒鉛粒子単独の場合よりも充放電容量が向上する。また黒鉛粒子に対して高比抵抗なＳｉ微粒子の周りに導電性炭素材を配置することで、Ｓｉ微粒子の導電性を見かけ上、向上させる。更にＳｉ微粒子を硬質炭素膜で被覆することにより、Ｌｉの吸蔵・放出に伴うＳｉ微粒子の体積膨張・収縮が機械的に抑えられる。更にまた、黒鉛粒子と複合粒子を非晶質炭素膜で覆うことにより、黒鉛粒子が直接に電解液に触れることなく電解液分解が抑制されるとともに、複合粒子が黒鉛粒子から脱落することがなく、更に充電による体積膨張に起因するＳｉ微粒子の微粉化を防止する。更に、結晶質Ｓｉ相中にＳｉＯ2相及びＳｉＣ相が析出することにより、相対的にＳｉ相の含有量が低減するとともに、Ｓｉ相に歪みを与えて結晶性を低下させ、過度のＬｉ吸蔵が抑制される。これにより、Ｌｉの吸蔵・放出によるＳｉ微粒子の膨張・収縮が適度に抑制される。ＳｉＯ2相及びＳｉＣ相はＬｉと反応しないためそれ自身は容量をもたないが、Ｌｉイオンの拡散を促進するとともに、Ｓｉ微粒子の体積膨張による微粉化が抑制される。更に、ＳｉＯ2相とＳｉＣ相の両方を含むため、上記の機能をより効果的に得ることができる。
以上のことから本発明の炭素質材料では、充放電容量を高くするとともに、Ｓｉ微粒子の体積膨張及び複合粒子の脱落、および充電による体積膨張に起因するＳｉ微粒子の微粉化を抑制して、サイクル特性の低下を防止することができる。
【００７１】
また、本発明のリチウム二次電池によれば、本発明に係る炭素質材料を負極として備えているので、エネルギー密度及びサイクル特性を向上させることができる。
【図面の簡単な説明】
【図１】 本発明の実施形態である炭素質材料の一例を示す断面模式図である。
【図２】 本発明の実施形態である炭素質材料の別の一例を示す断面模式図である。
【図３】 本発明の実施形態である炭素質材料の更に別の一例を示す断面模式図である。
【図４】 本発明の実施形態である炭素質材料の他の一例を示す断面模式図である。
【図５】 本発明の実施形態である炭素質材料に含まれる複合粒子の一例を示す断面模式図である。
【図６】 加熱後のＳｉ微粒子のＸ線回折パターンを示す図である。
【符号の説明】
１ 炭素質材料
２ 黒鉛粒子
３ 複合粒子
４ 非晶質炭素膜
５ Ｓｉ微粒子
６ 導電性炭素材
７ 硬質炭素膜[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a lithium secondary battery.Negative electrode active materialThe present invention relates to a carbonaceous material for use and a lithium secondary battery.
[0002]
[Prior art]
In order to meet the needs of portable electronic devices that are becoming smaller, lighter, and higher in performance, there is an urgent need to increase the capacity of lithium secondary batteries.
Incidentally, graphite, which is one of the negative electrode active materials of lithium secondary batteries, has a theoretical electric capacity of 372 mAh / g. However, in order to obtain a higher capacity negative electrode active material, it is amorphous. It is necessary to proceed with the development of carbon materials or new materials that can replace carbon materials.
Conventionally, silicon and its compounds have been studied as a new material to replace graphite. It is known that silicon and its compounds form an alloy with lithium itself and can provide a larger electric capacity than graphite.
Therefore, recently, as a negative electrode material for a lithium secondary battery, (1) a material obtained by simply mixing a silicon compound powder with graphite, or (2) a fine silicon compound on the graphite surface using a silane coupling agent or the like. A chemically fixed material, and (3) a material obtained by bonding or covering a graphite-based carbonaceous material and a metallic material such as Si with an amorphous carbonaceous material have been proposed.
[0003]
[Problems to be solved by the invention]
However, in the material of (1) above, since the graphite and the silicon compound are not necessarily in close contact with each other, the silicon compound is liberated from the graphite when the graphite expands and contracts due to the progress of the charge / discharge cycle. Since the electron conductivity itself is low, the silicon compound is not sufficiently used as the negative electrode active material, and there is a problem that the cycle characteristics of the lithium secondary battery are deteriorated.
[0004]
In the material (2), the charge / discharge cycle is maintained in a state where the silicon compound is in close contact with the graphite during the initial stage. Therefore, the silicon compound functions as a negative electrode active material like graphite, but the charge / discharge cycle proceeds. And the silicon compound itself expands along with the alloy formation with lithium, thereby breaking the bond by the silane coupling agent and releasing the silicon compound from the graphite, the silicon compound is not sufficiently utilized as the negative electrode active material, There existed a subject that the cycling characteristics of a lithium secondary battery fell.
Moreover, the silane coupling process performed at the time of manufacture of negative electrode material may not be performed uniformly, but the subject that the negative electrode material of the stable quality was not obtained easily occurred.
[0005]
Further, the same problem as the material (2) occurs in the material (3). That is, as the charge / discharge cycle progresses, the expansion of the metal material itself due to the formation of an alloy with lithium breaks the bond due to the amorphous carbon material and the metal material is released from the graphite-based carbon material, and the metal material is activated by the negative electrode. There is a problem that the cycle characteristics of the lithium secondary battery are deteriorated because the material is not sufficiently used as a substance.
[0006]
  The present invention has been made in view of the above circumstances, and has high charge / discharge capacity and at the same time excellent cycle characteristics.For negative electrode active material of lithium secondary batteryAn object is to provide a carbonaceous material and to provide a lithium secondary battery having the carbonaceous material.
[0007]
[Means for Solving the Problems]
  In order to achieve the above object, the present invention employs the following configuration.
  Of the present inventionFor negative electrode active material of lithium secondary batteryThe carbonaceous material contains composite particles having at least silicon and carbon and having a particle diameter smaller than that of the graphite particles around the graphite particles having a (002) plane spacing d002 of less than 0.337 nm by X-ray wide angle diffraction. The graphite particles and the composite particles are dispersedly arranged and covered with an amorphous carbon film having a surface interval d002 of 0.37 nm or more, and the composite particles are surrounded by Si fine particles made of crystalline silicon. A conductive carbon material is disposed on the Si fine particles and the conductive carbon material is covered with a hard carbon film, and the Si fine particles are SiO in the crystalline Si phase.2A phase and a SiC phase are precipitated.
[0008]
In the present invention, the meaning of “around” represents the positional relationship of the composite particles with respect to the graphite particles, and means “on or near the surface” of the graphite particles. Further, the meaning of “around” represents the positional relationship of the conductive carbon material with respect to the Si fine particles, and means “on or near the surface” of the Si fine particles.
Further, the meaning of “dispersed and arranged” means a state in which a plurality of composite particles are located on the surface of the graphite particles in a state of being dispersed or dispersed apart from each other without being aggregated.
The meaning of “coating” means a state in which the particles to be coated are bonded together by completely covering the particles to be coated. In this case, the coating target particles do not necessarily have to be in direct contact.
Specifically, covering the graphite particles and the composite particles with the amorphous carbon film means that the graphite particles and the composite particles are completely covered with the amorphous carbon film so that the graphite particles and the composite particles are bonded, or amorphous. This means that the composite particles were embedded in the carbonaceous film and brought close to the surface of the graphite particles.
Similarly, covering the Si fine particles and the conductive carbon material with the hard carbon film means that the Si fine particles and the conductive carbon material are completely covered with the hard carbon film to bond the Si fine particles and the conductive carbon material, It means that a conductive carbon material was embedded in the film and brought close to the surface of the Si fine particles.
Furthermore, the meaning of “precipitation” is a term for explaining the state of the crystal phase, and means a state in which a precipitation phase having a composition different from that of the parent phase is formed in the parent phase. That is, SiO2This means that the phase and the SiC phase are inseparably contained in the Si phase.2It does not mean that the phase and the SiC phase are physically separated from each other.
[0009]
In such a carbonaceous material, since the graphite particles and the Si fine particles occlude Li, the charge / discharge capacity is improved as compared with the case of the graphite particles alone.
Further, the conductivity of the Si fine particles is apparently improved by arranging a conductive carbon material around the Si fine particles having a high specific resistance to the graphite particles.
Further, by coating the Si fine particles with the hard carbon film, volume expansion / contraction of the Si fine particles accompanying the insertion / release of Li can be mechanically suppressed.
Furthermore, by covering the graphite particles and composite particles with an amorphous carbon film, the decomposition of the electrolytic solution is suppressed without the graphite particles touching the electrolytic solution directly, and the composite particles are not dropped from the graphite particles. Furthermore, the micronization of Si fine particles due to volume expansion due to charging is prevented.
[0010]
Furthermore, SiO in the crystalline Si phase2By precipitating the phase and the SiC phase, the content of the Si phase is relatively reduced, and the Si phase is distorted to reduce crystallinity, thereby suppressing excessive Li occlusion. Thereby, the expansion / contraction of the Si fine particles due to the insertion / release of Li is moderately suppressed. SiO2Since the phase and SiC phase do not react with Li, they do not have a capacity themselves, but they promote the diffusion of Li ions and suppress pulverization due to the volume expansion of Si fine particles.
Furthermore, SiO2Since both the phase and the SiC phase are included, the above function can be obtained more effectively.
From the above, in the carbonaceous material of the present invention, while increasing the charge / discharge capacity, suppressing the pulverization of the Si fine particles due to the volume expansion of the Si fine particles and the dropping of the composite particles, and the volume expansion due to charging, It becomes possible to prevent deterioration of cycle characteristics.
In particular, it is possible to prevent dissociation from the graphite particles due to the volume expansion of the Si fine particles, and to more effectively prevent a decrease in cycle efficiency. Further, by increasing the diffusion rate of Li ions, it is possible to quickly occlude / release Li ions even in an electrode filled with an active material at a high density, thereby improving charge / discharge efficiency.
[0011]
  The present inventionFor negative electrode active material of lithium secondary batteryThe carbonaceous material is the carbonaceous material described above, and the diffraction intensity of the (111) plane of the Si phase by X-ray wide angle diffraction is expressed as P.SiAnd said SiO2The diffraction intensity of the (111) plane of the phase is PSiO2And the diffraction intensity of the (111) plane of the SiC phase is PSiCPSiO2/ PSiIs 0.005 or more and 0.1 or less, and / or PSiC/ PSiIs 0.005 or more and 0.1 or less.
[0012]
In such a carbonaceous material, since the diffraction intensity ratio of each phase is in the above range, the Si phase content does not extremely decrease, and the Li occlusion amount does not decrease. In addition, SiO2By optimizing the contents of the phase and the SiC phase, the volume expansion / contraction of the Si fine particles is suppressed.
Therefore, the charge / discharge capacity of the carbonaceous material is increased, and further, the dissociation from the graphite particles due to the volume expansion of the Si fine particles and the pulverization of the Si fine particles due to the volume expansion due to the charge are prevented, thereby preventing a decrease in cycle efficiency. Is possible.
[0013]
  The present inventionFor negative electrode active material of lithium secondary batteryThe carbonaceous material is the carbonaceous material described above, wherein the particle size of the graphite particles is in a range of 2 μm or more and 70 μm or less, and the particle size of the composite particles is in a range of more than 50 nm and 2 μm or less, The amorphous carbon film has a thickness in the range of 50 nm to 5 μm.
[0014]
If the particle size of the graphite particles is less than 2 μm, the particle size of the graphite particles is relatively smaller than the particle size of the composite particles, and it is difficult to uniformly attach the composite particles to the surface of the graphite particles. When the particle size exceeds 70 μm, the adhesion to the current collector is lowered and the voids in the electrode are increased, which is not preferable.
Also, the particle size of the composite particles is more than 50 nm and not more than 2 μm, preferably more than 50 nm and not more than 500 nm in order to disperse and arrange the composite particles on the surface of the graphite particles. This is because the minimum particle size needs to be 2 μm or less, and if the particle size is 500 nm or less, the volume change of the composite particles due to expansion / contraction can be reduced. On the other hand, when the particle size is 50 nm or less, the disorder of the crystal structure of the Si fine particles contained in the composite particles becomes large, and the Li occlusion amount decreases, which is not preferable.
Furthermore, if the film thickness of the amorphous carbon film is less than 50 nm, the graphite particles may not be completely covered with the amorphous carbon film, and it will not be possible to prevent the composite particles from falling off the graphite particles, and also prevent the electrolyte from decomposing. Since it may be impossible to do so, it is not preferable. If the film thickness exceeds 5 μm, lithium ions do not reach the graphite particles, and the amount of Li occlusion is reduced, resulting in a decrease in charge / discharge capacity.
[0015]
  The present inventionFor negative electrode active material of lithium secondary batteryThe carbonaceous material is the carbonaceous material described above, wherein the particle size of the Si fine particles is in the range of 10 nm to less than 2 μm, and the specific resistance of the conductive carbon material is 10-FourΩ · m or less and the bending strength of the hard carbon film is 500 kg / cm2In addition to the above, the film thickness is 10 nm or more and 1 μm or less.
[0016]
The reason why the particle size of the Si fine particles is 10 nm or more is to prevent the disorder of the crystal structure of the Si fine particles and improve the Li occlusion amount. The reason why the particle size is less than 2 μm is to reduce the particle size of the composite particles. This is to make it smaller than 2 μm which is the minimum particle size of the graphite particles.
In addition, the specific resistance of the conductive carbon material is 10-FourThe reason why it is less than Ω · m is to provide sufficient conductivity to the Si fine particles.
Furthermore, the bending strength of the hard carbon film is 500 kg / cm.2The reason for the above is to reduce the volume change by mechanically suppressing the expansion and contraction of the Si fine particles accompanying the insertion and release of Li, and the thickness of the hard carbon film is set to 10 nm or more and 1 μm or less. This is because when the film thickness is less than 10 nm, the binding force between the conductive carbon material and the Si fine particles is reduced and the effect of suppressing the volume expansion of the composite particles is lost. This is because the ions do not reach the Si fine particles and the charge / discharge capacity decreases, which is not preferable.
[0017]
  The lithium secondary battery of the present inventionFor negative electrode active materialThe carbonaceous material is the carbonaceous material described above, wherein the content of the composite particles is 1 wt% or more and 25 wt% or less.
[0018]
If the content of the composite particles is less than 1% by weight, it is not preferable because a sufficient discharge capacity exceeding the case where only the carbon material is used as an active material cannot be obtained.
On the other hand, if the content exceeds 25% by weight, the contribution of the carbon material portion is reduced, and the voltage increases from the initial stage of discharge to near the reaction potential of Si, which is not preferable. This is not preferable because volume expansion / contraction is likely to occur due to Si fine particles, and cycle characteristics deteriorate.
[0019]
  Next, a lithium secondary battery of the present invention is characterized by including any of the carbonaceous materials described above. Such a lithium secondary battery includes, for example, a positive electrode, an electrolyte, and the negative electrode material.(Negative electrode active material)And having various shapes such as a cylindrical shape, a square shape, a coin shape, and a sheet shape. In addition, the lithium secondary battery of the present invention is not limited to the form described here, and may be composed of other forms.
  According to the lithium secondary battery, a lithium secondary battery having high energy density and excellent cycle characteristics can be configured.
[0020]
  Next, the present inventionFor negative electrode active material of lithium secondary batteryIn the method for producing a carbonaceous material, Si fine particles made of crystalline silicon are baked at 1300 ° C. or higher and 1400 ° C. or lower in a carbon crucible, so that SiO in the crystalline Si phase is obtained.2A step of precipitating a phase and a SiC phase, attaching a conductive carbon material to the Si fine particles, forming a polymer material film covering the Si fine particles to form a composite particle precursor, and further firing the composite particle precursor A step of obtaining composite particles by using the polymer film as a hard carbon film,The composite particleAnd forming a polymer material film covering the graphite particles to form a carbonaceous material precursor, and further firing the carbonaceous material precursor to form the polymer film.Surface spacing d of 0.37 nm or more 002 HaveAnd a step of obtaining a carbonaceous material as an amorphous carbon film.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
  Hereinafter, embodiments of the present invention will be described with reference to the drawings.
  1 to 4 show the lithium secondary battery of the present invention.For negative electrode active materialThe cross-sectional schematic diagram of a carbonaceous material is shown. This carbonaceous material is formed by dispersing composite particles around graphite particles and covering the graphite particles and composite particles with an amorphous carbon film.
[0022]
Here, “around” represents the positional relationship of the composite particles with respect to the graphite particles, and means “on or near the surface” of the graphite particles. That is, it includes a state in which the composite particles are bonded to the surface of the graphite particles and the composite particles are spaced from the surface of the graphite particles and positioned around the graphite particles.
Further, “dispersed and arranged” means a state in which a plurality of composite particles are dispersed on each other and are bonded to the surface of the graphite particles or slightly spaced from the surface. The composite particles may be in contact with each other to the extent that they do not aggregate.
“Coating” means a state in which the particles to be coated are bonded together by completely covering the particles to be coated. In this case, the coating target particles do not necessarily have to be in direct contact.
Specifically, covering the graphite particles and the composite particles with the amorphous carbon film means that the graphite particles and the composite particles are completely covered with the amorphous carbon film so that the graphite particles and the composite particles are bonded, or amorphous. This means that the composite particles were embedded in the carbonaceous film and brought close to the surface of the graphite particles.
Accordingly, the carbonaceous material of the present invention includes various forms as shown below.
[0023]
For example, the carbonaceous material 1 shown in FIG. 1 is bonded to the surface of the graphite particle 2 in a state where a plurality of composite particles 3 are dispersed, and the amorphous carbon film 4 is larger than the particle size of the composite particles 3. The graphite particles 2 and the composite particles 3 are coated with a small and uniform film thickness.
[0024]
2 is bonded to the surface of a plurality of graphite particles 2 in a state where a plurality of composite particles 3 are dispersed with each other, and the amorphous carbon film 4 has a particle size of the composite particles 3. The graphite particles 2 and the composite particles 3 are formed to have a larger and more uniform film thickness, and a plurality of graphite particles 2 are combined by the amorphous carbon film 4. .
2 shows a state in which two or three graphite particles 2 are combined by an amorphous carbon film 4, the present invention is not limited to this, and four or more graphite particles 2. May be combined.
[0025]
Further, the carbonaceous material 1 shown in FIG. 3 is bonded to the surface of the graphite particle 2 in a state where a plurality of composite particles 3 are dispersed with each other, and the amorphous carbon film 4 connects the graphite particles 2 and the composite particles 3. It is configured by coating. The amorphous carbon film 4 shown in FIG. 3 has a non-uniform film thickness. For example, the portion covering only the graphite particles 2 is set larger than the particle size of the composite particles 3. It is set smaller than the particle size of the composite particles 3.
[0026]
Further, the carbonaceous material 1 shown in FIG. 4 is bonded to the surface of the graphite particle 2 in a state where a plurality of composite particles 3 are dispersed with each other, and the amorphous carbon film 4 connects the graphite particles 2 and the composite particles 3. It is configured by coating. The amorphous carbon film 4 shown in FIG. 4 has a non-uniform film thickness. For example, the portion covering only the graphite particles 2 is set larger than the particle diameter of the composite particles 3. It is set smaller than the particle diameter of the composite particles 3. Moreover, the surface of the amorphous carbon film 4 is formed on a smooth surface without irregularities without reflecting the shape of the composite particles 3.
[0027]
The carbonaceous material of the present invention is not limited to those shown in FIGS. 1 to 4 and may be any material as long as the meanings of the above terms are satisfied.
[0028]
As the graphite particles 1 contained in the carbonaceous material, those having a (002) plane spacing d002 of 0.335 nm or more and less than 0.337 nm by X-ray wide angle diffraction are preferably used, and 0.335 nm or more and 0.340 nm are used. The following are more preferable.
When the interplanar spacing d002 is 0.337 nm or more, the crystallinity of the graphite particles decreases, the initial irreversible capacity increases remarkably, and the electron conductivity decreases, which is not preferable.
The particle size of the graphite particles 2 is preferably in the range of 2 μm to 70 μm.
When the particle size of the graphite particles 2 is less than 2 μm, the particle size of the graphite particles 2 is relatively smaller than the particle size of the composite particles 3... And the composite particles 3. This is not preferable because it becomes difficult, and if the particle size exceeds 70 μm, the adhesion to the current collector is lowered and the gap in the electrode is also increased.
[0029]
Next, as shown in FIGS. 1 to 4, the amorphous carbon film 4 covers the graphite particles 2 and the composite particles 3, and has the composite particles 3 attached on the surface of the graphite particles 2. The amorphous carbon film 4 also has an action of bonding the graphite particles 2... As shown in FIG.
The amorphous carbon film 4 is formed by heat-treating at least one of a thermoplastic resin, a thermosetting resin, a vinyl resin, a cellulose resin, a phenol resin, a coal pitch material, a petroleum pitch material, and a tar material. In this way, the graphitization is not relatively advanced, it is amorphous, and it has an interplanar spacing d002 of 0.37 nm or more. Since the amorphous carbon film 4 is amorphous, there is no possibility of decomposition even when the organic electrolyte touches the amorphous carbon film 4, and the charge / discharge efficiency of the carbonaceous material 1 can be increased.
If the interplanar spacing d002 of the amorphous carbon film 4 is less than 0.37 nm, the crystallinity of the amorphous carbon film 4 is improved, the graphite structure is approached, and the organic electrolyte may be decomposed. Absent.
[0030]
Further, since the composite particles 3 are arranged on the surface of the graphite particles 2 by the amorphous carbon film 4, the relatively high specific resistance composite particles 3 are prevented from being released from the graphite particles 2, Generation | occurrence | production of the composite particle 3 ... which does not contribute to charging / discharging reaction can be prevented.
The amorphous carbon film 4 is formed, for example, by dissolving the above-mentioned thermoplastic resin, thermosetting resin, etc. in a solvent, and also introducing graphite particles 2 so that the surface of the graphite particles 2 is thermoplastic resin, thermosetting. Since it is obtained by precipitating a conductive resin and firing it, the entire graphite particles 2 can be completely covered, and the density is relatively low and lithium ions are easily transmitted. In addition, the reaction between the composite particles 3 and lithium ions is not hindered.
The film thickness of the amorphous carbon film 4 is preferably in the range of 50 nm to 5 μm. If the film thickness is less than 50 nm, the graphite particles 2 are not completely covered, and the composite particles 3... May fall off from the graphite particles 2, which is not preferable. If the film thickness exceeds 5 μm, the irreversible capacity increases. Absent.
[0031]
Next, as shown in FIG. 5, the composite particles 3... Have conductive carbon materials 6 arranged around the Si fine particles 5, and the Si fine particles 5 and the conductive carbon materials 6. It is coated.
Further, the Si fine particles 3 are made of SiO in the crystalline Si phase.2Phase and SiC phase are precipitated.
Here, “around” represents the positional relationship of the conductive carbon material 6 to the Si fine particles 5 and means “on or near the surface” of the Si fine particles 5. That is, it includes a state in which the conductive carbon materials 6 are bonded to the surface of the Si fine particles 5 and the conductive carbon materials 6 are spaced from the surface of the Si fine particles 5 and positioned around the Si fine particles 5.
The Si fine particles 5 and the conductive carbon material 6 are covered with the hard carbon film 7. The Si fine particles 5 and the conductive carbon material 6 are completely covered with the hard carbon film 7 so that the Si fine particles 5 and the conductive carbon material 7 are covered. This includes bonding the raw materials 6... And embedding the conductive carbon materials 6 in the hard carbon film 7 so as to be close to the surface of the Si fine particles 5.
[0032]
Furthermore, “precipitation” is a term that describes the state of the crystal phase, and means a state in which a precipitation phase having a composition different from that of the parent phase is formed in the parent phase. That is, SiO2This means that the phase and the SiC phase are inseparably contained in the Si phase.2It does not mean that the phase and the SiC phase are physically separated from each other.
[0033]
The particle diameter of the composite particle 3 is preferably in the range of more than 50 nm and 2 μm or less, and more preferably in the range of more than 50 nm and 500 nm or less.
The particle size of the composite particles 3 is set to 2 μm or less in order to disperse and arrange the composite particles 3 on the surface of the graphite particles 2. The particle size of the composite particles 3 is set to 2 μm or less which is the minimum particle size of the graphite particles 2. This is because if the particle size is 500 nm or less, the volume change due to the expansion and contraction of the Si fine particles 5 accompanying the occlusion and release of lithium can be reduced. Further, the reason why the lower limit of the particle diameter exceeds 50 nm is that when it is 50 nm or less, the crystal structure of the Si fine particles 5 contained in the composite particles 3 is greatly disturbed, the Li occlusion amount is reduced, and the charge / discharge capacity is reduced. This is because there is a possibility that it may decrease.
[0034]
The Si fine particles 5 contain crystalline silicon (Si phase) as a main component, and SiO 22A phase and a SiC phase are precipitated, and the particle diameter is in the range of 10 nm or more and less than 2 μm.
Silicon is an element that forms an alloy with lithium, and an alloy is formed when lithium ions act on the Si phase composed of silicon. In particular, lithium ions penetrate into the surface of the Si fine particles 5 or voids inside the Si fine particles 5 to form an alloy, whereby the Si fine particles 5 themselves expand.
[0035]
The Si fine particles 5 have SiO2A phase and a SiC phase are included, and these phases do not react with lithium and thus do not have a capacity per se, but have an effect of promoting diffusion of lithium ions.
Therefore, SiO in the Si phase2When the phase and the SiC phase are included, the diffusion rate of lithium ions in the Si phase is improved, and for example, even in an electrode filled with this carbonaceous material at a high density, quick insertion and extraction of Li ions can be performed. Charge / discharge efficiency can be improved.
[0036]
In addition, the Si fine particles 5 have SiO2When the phase and the SiC phase are contained, the content of the Si phase is relatively lowered, and the Si phase is distorted to lower the crystallinity. As a result, the amount of occlusion of lithium ions slightly decreases, but at the same time, the expansion and contraction of the Si fine particles accompanying the occlusion / release of lithium are moderately suppressed. Thereby, pulverization due to the volume expansion of the Si fine particles is suppressed, and the composite particles are prevented from falling off due to the volume expansion of the Si fine particles, thereby preventing deterioration of cycle characteristics.
[0037]
Specifically, the diffraction intensity of the (111) plane of the Si phase by X-ray wide angle diffraction is expressed as PSiAnd said SiO2The diffraction intensity of the (111) plane of the phase is PSiO2And the diffraction intensity of the (111) plane of the SiC phase is PSiCPSiO2/ PSiIs 0.005 or more and 0.1 or less, and / or PSiC/ PSiIs preferably 0.005 or more and 0.1 or less.
PSiO2/ PSiIs less than 0.005, SiO2This is not preferable because the phase content is reduced, the expansion and contraction of the Si fine particles 5 cannot be suppressed, and the diffusion rate of lithium is reduced. PSiO2/ PSiIf it exceeds 0.1, the content of the Si phase in the Si fine particles 5 is lowered, and the charge / discharge capacity is lowered.
PSiC/ PSiIs less than 0.005, it is not preferable because the content of the SiC phase is reduced, the expansion and contraction of the Si fine particles 5 cannot be suppressed, and the diffusion rate of lithium is reduced.SiC/ PSiIf it exceeds 0.1, the content of the Si phase in the Si fine particles 5 is lowered, and the charge / discharge capacity is lowered.
In addition, SiO2The phases and SiC phases alone cannot sufficiently exhibit the above effects. Therefore, in the present invention, SiO2It is preferable to include both the phase and the SiC phase.
[0038]
The reason why the particle size of the Si fine particles 5 is 10 nm or more is to prevent the disorder of the crystal structure of the Si fine particles 5 and improve the Li storage amount. The reason why the particle size is less than 2 μm This is because the particle size of 3 needs to be smaller than 2 μm, which is the minimum particle size of the graphite particles 2.
[0039]
Next, the conductive carbon materials 6 are arranged on or near the surface of the Si fine particles 5, and in FIG. 5, the particulate conductive carbon materials 6 are arranged around the Si fine particles 5. However, the shape of the conductive carbon material 6 is not limited to a particle shape, and may be various forms such as a film shape, a layer shape, and a fiber shape.
The conductive carbon material 6 is located on the surface of the Si fine particles 5 that are semiconductors and imparts apparent conductivity to the Si fine particles 5. The specific resistance of the conductive carbon material 6 is 10-FourA range of Ω · m or less is preferred. Specific resistance is 10-FourIf it exceeds Ω · m, the apparent conductivity of the Si fine particles 5 decreases, and the charge / discharge reaction of lithium ions to the Si fine particles 5 does not proceed smoothly, and the charge / discharge capacity of the carbonaceous material can be improved. Since it disappears, it is not preferable.
Examples of the conductive carbon material 6... Include carbon black, ketjen black, vapor grown carbon fiber (VGCF), and the like.
[0040]
The hard carbon film 7 covers the Si fine particles 5 and the conductive carbon materials 6... And the conductive carbon materials 6 are arranged on the surface of the Si fine particles 5. This hard carbon film 7 is obtained by firing polyvinyl alcohol, phenol resin, or the like, and has a bending strength of 500 kg / cm.2In addition to the above, the film thickness is 10 nm or more and 1 μm or less.
[0041]
The hard carbon film 7 is for preventing the release of the composite particles 3 from the graphite particles 2 caused by the expansion and contraction of the Si fine particles 5 accompanying the charge / discharge reaction of lithium ions. Mechanically suppress shrinkage. Therefore, the bending strength of the hard carbon film 7 is 500 kg / cm.2It is preferable to make it above. Bending strength is 500kg / cm2If it is less than the range, the expansion / contraction of the Si fine particles 5 cannot be mechanically suppressed, and the composite particles 3 may be released from the graphite particles 2, which is not preferable.
Moreover, when the film thickness of the hard carbon film 7 is less than 10 nm, the binding force between the conductive carbon material 6... And the Si fine particles 5 is lowered, and the effect of suppressing the volume expansion of the composite particles 3 is lowered. . Further, if the film thickness exceeds 1 μm, the irreversible capacity due to amorphous carbon is increased, which is not preferable.
[0042]
And it is preferable that content of said composite particle 3 in the carbonaceous material of this invention is 1 to 25 weight%. If the content of the composite particles 3 is less than 1% by weight, it is not preferable because a sufficient discharge capacity that exceeds the case of using only a carbon material as an active material cannot be obtained. On the other hand, if the content exceeds 25% by weight, the contribution of the carbon material portion is reduced, reaching the reaction potential of Si from the beginning of discharge, and the average voltage of the battery is lowered. Narrowing and re-aggregation are likely to cause volume expansion / contraction due to the Si fine particles 5, and cycle characteristics are deteriorated.
[0043]
When the carbonaceous material 1 reacts with lithium ions, the lithium ions are mainly stored in the graphite particles 2 and combine with the Si fine particles 5 to form an alloy. The conductive carbon material 6 is adhered to the surface of the Si fine particles 5 and the conductivity is apparently high, and lithium ions are easily alloyed with the Si fine particles 5.
At this time, the volume of the graphite particles 2 and the Si fine particles 5 expands, but since the Si fine particles 5 are covered with the hard carbon film 7, the volume expansion is mechanically suppressed, and the composite containing the Si fine particles 5. The particles 3 are not dissociated from the graphite particles 2.
Further, the Si fine particles 5 ... have a Si phase and SiO.2Since the phase and the SiC phase are included, the amount of occlusion of lithium ions is suppressed, and the volume expansion of the Si fine particles 5 is moderately suppressed. This also makes the composite particles 3 including the Si fine particles 5 ... graphite particles 2. Will not dissociate.
Therefore, the Si fine particles 5 can always contribute to the charge / discharge reaction, and the charge / discharge capacity of the carbonaceous material 1 does not decrease even if the charge / discharge cycle proceeds.
[0044]
Further, by covering the graphite particles 2 and the composite particles 3 with the amorphous carbon film 4, the graphite particles 2 do not directly touch the organic electrolyte solution, and the decomposition of the organic electrolyte solution is suppressed. Further, the composite particles 3 are not detached from the graphite particles 2, and further, the fine particles of the Si fine particles 5 due to volume expansion due to charging are prevented.
[0045]
Therefore, according to said carbonaceous material 1, while charging / discharging capacity | capacitance is made high, pulverization of Si microparticles 5 ... resulting from the volume expansion of Si microparticles 5 ..., dropping off of composite particles 3 ..., and volume expansion accompanying charging Can be suppressed and deterioration of cycle characteristics can be prevented.
[0046]
Said carbonaceous material can be manufactured as follows, for example.
The production of the carbonaceous material includes a step of producing composite particles and a step of mixing graphite particles with the obtained composite particles and coating them with an amorphous carbon film.
First, in the step of producing composite particles, Si fine particles consisting only of Si phase are prepared, and these Si fine particles are put into a carbon crucible and heated at about 1300 to 1400 ° C. for 120 to 300 minutes in an inert atmosphere. By this heating, carbon constituting the crucible and the Si phase react to precipitate a SiC phase in the Si fine particles, and slightly mixed oxygen reacts with the Si phase to cause SiO in the Si fine particles.2A phase precipitates.
However, when the heating temperature is less than 1300 ° C. and / or the heating time is less than 120 minutes, the SiC phase and SiO2The phase does not sufficiently precipitate, which is not preferable. When the heating temperature exceeds 1400 ° C., Si melts, which is not preferable. When the heating time exceeds 300 minutes, the SiC phase and SiO2This is not preferable because the amount of phase precipitation becomes excessive.
[0047]
Next, the Si fine particles after heating and the conductive carbon material are mixed by dry mixing or wet mixing. In the case of wet mixing, it is preferable to use a dispersion medium such as isopropyl alcohol, acetone, ethanol, water or the like.
[0048]
Next, the polymer material is dissolved in an appropriate solvent, and a mixture of the Si fine particles and the conductive carbon material is mixed into this solution, and then the solvent is removed. By removing the solvent, a composite particle precursor in which a polymer film is coated on Si fine particles and a conductive carbon material is formed.
In addition, it is preferable to use at least 1 sort (s) among a thermoplastic resin, a thermosetting resin, a vinyl-type resin, a cellulose resin, and a phenol-type resin as said polymeric material, and it is preferable to use especially a phenol resin. Coal pitch materials, petroleum pitch materials, tar materials and the like may be used.
[0049]
Next, the composite particle precursor is heat-treated to carbonize the polymer film to form a hard carbon film.
The heat treatment is preferably performed in a vacuum atmosphere or an inert gas atmosphere, the heat treatment temperature is preferably in the range of 800 ° C. to 1200 ° C., and the heat treatment time is preferably 120 minutes or longer.
When the heat treatment is performed in a vacuum atmosphere or an inert gas atmosphere, the polymer film is prevented from being oxidized and a good hard carbon film can be formed.
When the heat treatment temperature is less than 800 ° C., carbonization is not completely performed, the specific resistance of the hard carbon film is high, and it is difficult to insert and remove lithium ions, and when the heat treatment temperature exceeds 1200 ° C., Since Si microparticles are carbonized and SiC is generated excessively, it is not preferable.
Similarly, a heat treatment time of less than 120 minutes is not preferable because a uniform hard carbon film cannot be formed.
In this way, composite particles are obtained.
[0050]
In the next step, graphite particles are mixed with the obtained composite particles by dry mixing or wet mixing. In the case of wet mixing, it is preferable to use a dispersion medium such as isopropyl alcohol, acetone, ethanol, water or the like.
[0051]
Next, another polymer material is dissolved in an appropriate solvent, and a mixture of composite particles and graphite particles is mixed with this solution, and then the solvent is removed. By removing the solvent, a carbonaceous material precursor in which the polymer particles are coated with the composite particles and the graphite particles is formed.
In addition, it is preferable to use at least 1 sort (s) among a thermoplastic resin, a thermosetting resin, a vinyl resin, a cellulose resin, a phenol resin, etc. for said polymeric material, and it is preferable to use especially a phenol resin. Coal pitch materials, petroleum pitch materials, tar materials, etc. may be used.
[0052]
  Next, the polymer film is carbonized by heat treating the carbonaceous material precursor.Surface spacing d of 0.37 nm or more 002 HaveAn amorphous carbon film is formed.
  The heat treatment is preferably performed in a vacuum atmosphere or an inert gas atmosphere, the heat treatment temperature is preferably in the range of 800 ° C. to 1200 ° C., and the heat treatment time is preferably 120 minutes or longer.
  When the heat treatment is performed in a vacuum atmosphere or an inert gas atmosphere, the polymer film is prevented from being oxidized and a good amorphous carbon film can be formed.
  Note that if the heat treatment temperature is less than 800 ° C., the carbonization is not performed completely because of the low temperature, the specific resistance of the amorphous carbon film is high, and it is difficult to insert and remove lithium ions. If the temperature exceeds 1200 ° C., the Si fine particles are carbonized to generate excessive SiC, and the graphitization of the polymer film proceeds to reduce the strength of the amorphous carbon film.
  Similarly, a heat treatment time of less than 120 minutes is not preferable because a uniform hard carbon film cannot be formed.
  In this way, the carbonaceous material according to the present invention is obtained.
[0053]
A lithium secondary battery can be composed of a negative electrode having the above carbonaceous material, a positive electrode capable of inserting and extracting lithium, and an organic electrolyte.
As the positive electrode, for example, LiMn2OFourLiCoO2, LiNiO2LiFeO2, V2OFiveExamples thereof include a positive electrode material capable of occluding and releasing lithium, such as TiS and MoS, and a positive electrode material such as an organic disulfide compound or an organic polysulfide compound.
As a specific example of the positive electrode or the negative electrode, the above-mentioned positive electrode material or carbonaceous material is mixed with a binder and, if necessary, a conductive additive, and applied to a current collector made of a metal foil or a metal net. What was shape | molded in the sheet form can be illustrated.
[0054]
As the organic electrolyte, for example, an organic electrolytic solution in which a lithium salt is dissolved in an aprotic solvent can be exemplified.
As aprotic solvents, propylene carbonate, ethylene carbonate, butylene carbonate, benzonitrile, acetonitrile, tetrahydrofuran, 2-methyltetrahydrofuran, γ-butyrolactone, dioxolane, 4-methyldioxolane, N, N-dimethylformamide, dimethylacetamide, dimethyl Sulfoxide, dioxane, 1,2-dimethoxyethane, sulfolane, dichloroethane, chlorobenzene, nitrobenzene, dimethyl carbonate, methyl ethyl carbonate, diethyl carbonate, methyl propyl carbonate, methyl isopropyl carbonate, ethyl butyl carbonate, dipropyl carbonate, diisopropyl carbonate, dibutyl carbonate , Diethylene glycol, dimethyl An aprotic solvent such as ether, or a mixed solvent in which two or more of these solvents are mixed can be exemplified. In particular, any one of propylene carbonate, ethylene carbonate, and butylene carbonate must be included, and dimethyl carbonate, methyl ethyl It is preferable that any one of carbonate and diethyl carbonate is necessarily contained.
[0055]
Moreover, as a lithium salt, LiPF6, LiBFFour, LiSbF6, LiAsF6LiClOFour, LiCFThreeSOThree, Li (CFThreeSO2)2N, LiCFourF9SOThree, LiSbF6, LiAlOFour, LiAlClFour, LiN (CxF2x + 1SO2) (CyF2y Ten 1SO2) (Where x and y are natural numbers), LiCl, LiI, etc. can be exemplified by mixing one or two or more lithium salts, particularly LiPF.6, LiBFFourThose containing any one of these are preferred.
In addition to this, a conventionally known organic electrolyte for a lithium secondary battery may be used.
[0056]
As another example of the organic electrolyte, a polymer such as PEO or PVA mixed with any of the lithium salts described above, or a polymer having a high swellability impregnated with an organic electrolyte, a so-called polymer electrolyte May be used.
Furthermore, the lithium secondary battery of the present invention is not limited to the positive electrode, the negative electrode, and the electrolyte, and may include other members as necessary. For example, the lithium secondary battery may include a separator that separates the positive electrode and the negative electrode. .
[0057]
According to the above lithium secondary battery, since the carbonaceous material 1 is provided, a lithium secondary battery having high energy density and excellent cycle characteristics can be configured.
[0058]
【Example】
[Production of carbonaceous material of Experimental Example 1]
15 g of Si fine particles having an average particle size of 0.9 μm were put into a carbon crucible having an internal volume of 200 ml and heated at 1400 ° C. for 240 minutes in an argon gas atmosphere.
Next, 1 part by weight of carbon black was mixed with 2 parts by weight of Si fine particles after heating. Carbon black has a specific resistance of 10-FourIt was below Ω · m.
Next, a solution in which 10 parts by weight of a phenol resin was dissolved in isopropyl alcohol was prepared, and the mixture of the Si fine particles and carbon black was mixed with this solution and stirred sufficiently, and then the solvent was removed. In this way, a composite particle precursor formed by adhering carbon black and a phenol resin film to the surface of the Si fine particles was formed.
Next, this composite particle precursor was heat-treated at 1000 ° C. for 180 minutes in an argon gas atmosphere to carbonize the phenol resin film to form a hard carbon film having a thickness of 0.05 μm.
When the phenol resin is carbonized alone under the same conditions as described above, the bending strength of the resulting carbide is 800 kg / cm.2Therefore, it is estimated that the bending strength of the hard carbon film is the same.
In this way, composite particles were obtained.
[0059]
Next, 5 parts by weight of the composite particles were added to 95 parts by weight of natural graphite having an average particle diameter of 15 μm, and isopropyl alcohol was further added to perform wet mixing. In addition, the interplanar spacing d002 of the (002) plane by X-ray wide angle diffraction of natural graphite was 0.3355 nm.
Next, an isopropyl alcohol solution containing 10 parts by weight of a phenol resin was added to and mixed with the above mixture of natural graphite and composite particles, and then isopropyl alcohol was evaporated. In this way, a carbonaceous material precursor formed by adhering composite particles and a phenol resin film to the surface of natural graphite was formed.
[0060]
Next, this carbonaceous material precursor was baked at 1000 ° C. (1273 K) in a vacuum atmosphere to carbonize the phenol resin to obtain an amorphous carbon film having a thickness of 0.05 μm.
When the phenol resin is carbonized alone under the same conditions as described above, the surface spacing d002 of the (002) plane of the resulting carbide is about 0.39 nm. Is estimated to be similar.
Thus, the carbonaceous material of Experimental Example 1 was obtained.
[0061]
[Production of carbonaceous material of Experimental Example 2]
Composite particles and a carbonaceous material were obtained in the same manner as in Experimental Example 1 except that Si fine particles having an average particle diameter of 2.0 μm were used.
[0062]
[Production of Carbonaceous Material of Experimental Example 3]
Further, in place of the composite particles, 5 parts by weight of Si fine particles having a particle size of 0.9 μm were mixed with 95 parts by weight of natural graphite, and a phenol resin film was formed and fired. The carbonaceous material of Example 3 was obtained.
[0063]
[Create test cell for charge / discharge test]
Polyvinylidene fluoride was mixed with the carbonaceous materials of Experimental Examples 1 and 2, and N-methylpyrrolidone was further added to form a slurry liquid. This slurry solution was applied to a copper foil having a thickness of 14 μm by a doctor blade method and dried in a vacuum atmosphere at 120 ° C. for 24 hours to volatilize N-methylpyrrolidone. In this way, a negative electrode mixture having a thickness of 100 μm was laminated on the copper foil. The content of polyvinylidene fluoride in the negative electrode mixture is 8% by weight, and the density of the negative electrode mixture is 1.5 g / cm.ThreeThat was all.
And the copper foil which laminated | stacked the negative electrode compound material was punched out to the circle | round | yen of diameter 13mm, and it was set as the negative electrode of Experimental example 1-2.
[0064]
Further, the negative electrode of Experimental Example 3 was prepared in the same manner as described above except that polyvinylidene fluoride and N-methylpyrrolidone were added to the carbonaceous material of Experimental Example 3 and carbon black was further added to form a slurry liquid. Obtained. The content of polyvinylidene fluoride in the negative electrode mixture was 8% by weight, and the content of carbon black was 2.5% by weight.
[0065]
The negative electrode of Experimental Examples 1 and 2 and Experimental Example 3 was used as a working electrode, a metal lithium foil punched out in a circle was used as a counter electrode, a separator made of a porous polypropylene film was inserted between the working electrode and the counter electrode, and an electrolyte solution was obtained. A coin-type test cell using LiPF6 dissolved in a mixed solvent of dimethyl carbonate (DMC), diethyl carbonate (DEC) and ethylene carbonate (EC) as a solute to a concentration of 1 (mol / L). It was created.
The charge / discharge current density is 0.2 C, and the charge end voltage is 0 V (L i / L i+), And the discharge end voltage is 1.5 V (Li / Li+) As a charge / discharge test.
[0066]
Table 1 shows the discharge capacity and charge / discharge efficiency in the first cycle. Further, a capacity ratio (2nd / 1st) obtained by dividing the discharge capacity at the second cycle by the discharge capacity at the first cycle was obtained. The results are also shown in Table 1.
[0067]
[Table 1]
Figure 0004104830
[0068]
As shown in Table 1, it can be seen that the discharge capacity at the first cycle is lower in Experimental Example 1 than in Experimental Example 3.
This is because the Si fine particles are heated in a carbon crucible, so that the SiC phase and the SiO phase are contained in the Si phase of the Si fine particles.2This is presumably because the phase precipitated and the content of Si phase forming an alloy with lithium was relatively reduced.
FIG. 6 shows an X-ray diffraction pattern of Si fine particles after heating. As apparent from FIG. 6, in addition to the Si phase, the SiC phase and SiO2A diffraction peak originating from the phase is observed. The diffraction intensity of the (111) plane of the Si phase is PSiAnd SiO2The diffraction intensity of the (111) plane of the phase is PSiO2And the diffraction intensity of the (111) plane of the SiC phase is PSiC, P from FIG.SiO2/ PSi= 0.010 and PSiC/ PSiIt can be seen that = 0.042.
[0069]
Next, the charge / discharge efficiency in the first cycle is 90% in the comparative example, while the experimental example 1 reaches 90%.
In addition, regarding the capacity ratio (2nd / 1st), Experimental Example 1 has reached nearly 98%, while Experimental Example 3 has remained at about 92%.
This is because the SiC phase and SiO in Si fine particles.2Since the phase is precipitated and the content of the Si phase forming an alloy with lithium is relatively reduced, the expansion and contraction of the Si fine particles themselves are moderately suppressed, thereby reducing the release of the composite particles from the graphite. This is thought to be due to the improved cycle characteristics.
Further, when the results of Experimental Examples 1 and 2 are compared, Experimental Example 2 in which the average particle size of the Si fine particles is 2.0 μm is lower than Experimental Example 1 in both initial charge and discharge efficiency and capacity ratio (2nd / 1st). Yes. This is because when the Si particle size is about 2.0 μm or more, the expansion of Si due to charging is large, and the SiC phase and SiO deposited by firing are reduced.2This is probably because the effect of the phase alone cannot suppress the pulverization of Si and the removal from the electrode plate.
[0070]
【The invention's effect】
As described above in detail, according to the carbonaceous material of the present invention, since the graphite particles and the Si fine particles occlude Li, the charge / discharge capacity is improved as compared with the case of the graphite particles alone. Further, the conductivity of the Si fine particles is apparently improved by arranging a conductive carbon material around the Si fine particles having a high specific resistance to the graphite particles. Further, by coating the Si fine particles with the hard carbon film, volume expansion / contraction of the Si fine particles accompanying the insertion / release of Li can be mechanically suppressed. Furthermore, by covering the graphite particles and composite particles with an amorphous carbon film, the decomposition of the electrolytic solution is suppressed without the graphite particles touching the electrolytic solution directly, and the composite particles are not dropped from the graphite particles. Furthermore, the micronization of Si fine particles due to volume expansion due to charging is prevented. Furthermore, SiO in the crystalline Si phase2By precipitating the phase and the SiC phase, the content of the Si phase is relatively reduced, and the Si phase is distorted to reduce crystallinity, thereby suppressing excessive Li occlusion. Thereby, the expansion / contraction of the Si fine particles due to the insertion / release of Li is moderately suppressed. SiO2Since the phase and SiC phase do not react with Li, they do not have a capacity themselves, but they promote the diffusion of Li ions and suppress pulverization due to the volume expansion of Si fine particles. Furthermore, SiO2Since both the phase and the SiC phase are included, the above function can be obtained more effectively.
From the above, in the carbonaceous material of the present invention, the charge / discharge capacity is increased, and the fine particles of Si fine particles caused by the volume expansion of Si fine particles and the drop of composite particles, and the volume expansion due to charging are suppressed, and the cycle It is possible to prevent deterioration of characteristics.
[0071]
Moreover, according to the lithium secondary battery of this invention, since the carbonaceous material which concerns on this invention is provided as a negative electrode, an energy density and cycling characteristics can be improved.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view showing an example of a carbonaceous material that is an embodiment of the present invention.
FIG. 2 is a schematic cross-sectional view showing another example of a carbonaceous material that is an embodiment of the present invention.
FIG. 3 is a schematic cross-sectional view showing still another example of a carbonaceous material that is an embodiment of the present invention.
FIG. 4 is a schematic cross-sectional view showing another example of a carbonaceous material that is an embodiment of the present invention.
FIG. 5 is a schematic cross-sectional view showing an example of composite particles contained in a carbonaceous material according to an embodiment of the present invention.
FIG. 6 is a diagram showing an X-ray diffraction pattern of Si fine particles after heating.
[Explanation of symbols]
1 Carbonaceous material
2 Graphite particles
3 composite particles
4 Amorphous carbon film
5 Si fine particles
6 Conductive carbon material
7 Hard carbon film

Claims (7)

Ｘ線広角回折による（００２）面の面間隔ｄ002が０．３３７nm未満である黒鉛粒子の周りに、珪素及び炭素を少なくとも含有するとともに前記黒鉛粒子より粒径が小さな複合粒子が分散して配置され、かつ前記黒鉛粒子及び前記複合粒子が０．３７ｎｍ以上の面間隔ｄ002を有する非晶質炭素膜によって被覆されてなり、
前記複合粒子は、結晶質珪素からなるＳｉ微粒子の周りに導電性炭素材が配置されるとともに前記Ｓｉ微粒子及び前記導電性炭素材が硬質炭素膜により被覆されてなり、
前記Ｓｉ微粒子は、結晶質Ｓｉ相中にＳｉＯ２相及びＳｉＣ相が析出したものであることを特徴とするリチウム二次電池の負極活物質用の炭素質材料。Composite particles containing at least silicon and carbon and having a particle size smaller than that of the graphite particles are dispersed around the graphite particles having a (002) plane distance d002 of less than 0.337 nm by X-ray wide angle diffraction. And the graphite particles and the composite particles are covered with an amorphous carbon film having an interplanar spacing d002 of 0.37 nm or more,
In the composite particles, a conductive carbon material is disposed around Si fine particles made of crystalline silicon, and the Si fine particles and the conductive carbon material are covered with a hard carbon film.
The carbonaceous material for a negative electrode active material of a lithium secondary battery, wherein the Si fine particles are obtained by depositing a SiO 2 phase and a SiC phase in a crystalline Si phase. Ｘ線広角回折による前記Ｓｉ相の（１１１）面の回折強度をＰＳｉとし、前記ＳｉＯ２相の（１１１）面の回折強度をＰＳｉＯ２とし、前記ＳｉＣ相の（１１１）面の回折強度をＰＳｉＣとしたとき、
ＰＳｉＯ２／ＰＳｉが０．００５以上０．１以下、及び／または、ＰＳｉＣ／ＰＳｉが０．００５以上０．１以下であることを特徴とする請求項１に記載のリチウム二次電池の負極活物質用の炭素質材料。The diffraction intensity of the (111) plane of the Si phase by X-ray wide angle diffraction is PSi, the diffraction intensity of the (111) plane of the SiO 2 phase is P 2 SiO2, and the diffraction intensity of the (111) plane of the SiC phase is P when the SiC,
2. The lithium secondary battery according to claim 1, wherein P SiO2 / P Si is 0.005 or more and 0.1 or less and / or P SiC / P Si is 0.005 or more and 0.1 or less. Carbonaceous material for negative electrode active material. 前記黒鉛粒子の粒径が２μｍ以上７０μｍ以下の範囲であり、前記複合粒子の粒径が５０ｎｍを越えて２μｍ以下の範囲であり、前記非晶質炭素膜の膜厚が５０ｎｍ以上５μｍ以下の範囲であることを特徴とする請求項１または請求項２に記載のリチウム二次電池の負極活物質用の炭素質材料。The particle size of the graphite particles is in the range of 2 μm or more and 70 μm or less, the particle size of the composite particles is in the range of more than 50 nm and 2 μm or less, and the film thickness of the amorphous carbon film is in the range of 50 nm or more and 5 μm or less. The carbonaceous material for a negative electrode active material of a lithium secondary battery according to claim 1 or 2, wherein the carbonaceous material is a lithium secondary battery . 前記Ｓｉ微粒子の粒径が１０ｎｍ以上２μｍ未満の範囲であり、前記導電性炭素材の比抵抗が１０−４Ω・ｍ以下であり、かつ前記硬質炭素膜の曲げ強度が５００ｋｇ／ｃｍ２以上であるとともに膜厚が１０ｎｍ以上１μｍ以下であることを特徴とする請求項１ないし請求項３のいずれかに記載のリチウム二次電池の負極活物質用の炭素質材料。In the particle diameter of the Si particles in the range of less than 2μm above 10 nm, a specific resistance of the conductive carbon material is not higher than 10 -4 Ω · m, and the bending strength of the hard carbon film is 500 kg / cm 2 or more The carbonaceous material for a negative electrode active material of a lithium secondary battery according to any one of claims 1 to 3, wherein the carbonaceous material has a thickness of 10 nm to 1 µm. 前記複合粒子の含有量が１重量％以上２５重量％以下であることを特徴とする請求項１ないし請求項４のいずれかに記載のリチウム二次電池の負極活物質用の炭素質材料。5. The carbonaceous material for a negative electrode active material of a lithium secondary battery according to claim 1, wherein the content of the composite particles is 1 wt% or more and 25 wt% or less. 請求項１ないし請求項５のいずれかに記載のリチウム二次電池の負極活物質用の炭素質材料を備えたことを特徴とするリチウム二次電池。A lithium secondary battery comprising the carbonaceous material for a negative electrode active material for a lithium secondary battery according to any one of claims 1 to 5. 結晶質珪素からなるＳｉ微粒子を炭素るつぼ中で１３００℃以上１４００℃以下で焼成することにより、結晶質Ｓｉ相中にＳｉＯ２相及びＳｉＣ相を析出させる工程と、
前記Ｓｉ微粒子に導電性炭素材を付着するとともに、該Ｓｉ微粒子を覆う高分子材料皮膜を形成して複合粒子前駆体とし、更に該複合粒子前駆体を焼成することにより前記高分子皮膜を硬質炭素膜として複合粒子を得る工程と、
黒鉛粒子に前記複合粒子を付着するとともに、該黒鉛粒子を覆う高分子材料皮膜を形成して炭素質材料前駆体とし、更に該炭素質材料前駆体を焼成することにより前記高分子皮膜を０．３７ｎｍ以上の面間隔ｄ 002 を有する非晶質炭素膜として炭素質材料を得る工程と
からなることを特徴とするリチウム二次電池の負極活物質用の炭素質材料の製造方法。A step of precipitating a SiO 2 phase and a SiC phase in the crystalline Si phase by firing Si fine particles made of crystalline silicon in a carbon crucible at 1300 ° C. or higher and 1400 ° C. or lower;
A conductive carbon material is attached to the Si fine particles, and a polymer material film covering the Si fine particles is formed to form a composite particle precursor, and the composite particle precursor is further baked to form the polymer film into hard carbon. Obtaining composite particles as a membrane;
The composite particles are adhered to the graphite particles, and a polymer material film covering the graphite particles is formed to form a carbonaceous material precursor . method of manufacturing a carbonaceous material for a negative electrode active material of a lithium secondary battery, characterized by comprising a step of obtaining a carbonaceous material as an amorphous carbon film having a plane spacing d 002 of more than 37 nm.
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