	US 12,476,237 B2
	Process for preparing silicon-containing composite particles
Jan Tillmann, Munich (DE); Christoph Dräger, Munich (DE); Alena Kalyakina, Munich (DE); Sebastian Kneissl, Kolbermoor (DE); Thomas Renner, Munich (DE); Markus Anderson, Abingdon (GB); Charles A. Mason, Abingdon (GB); José Medrano-Catalan, Abingdon (GB); Richard Gregory Taylor, Penarth (GB); and Joshua Whittam, East Hendred (GB)
Assigned to Wacker Chemie AG, Munich (DE); and Nexeon Limited, Abingdon (GB)
Appl. No. 18/031,894
Filed by WACKER CHEMIE AG, Munich (DE); and NEXEON LIMITED, Abingdon (GB)
PCT Filed Oct. 22, 2021, PCT No. PCT/EP2021/079421 § 371(c)(1), (2) Date Apr. 14, 2023, PCT Pub. No. WO2022/084545, PCT Pub. Date Apr. 28, 2022.
Application 18/031,894 is a continuation of application No. PCT/EP2020/083885, filed on Nov. 30, 2020.
Claims priority of application No. 2016900 (GB), filed on Oct. 23, 2020.
Prior Publication US 2023/0395774 A1, Dec. 7, 2023
Int. Cl. C23C 16/04 (2006.01); C04B 35/528 (2006.01); C04B 35/628 (2006.01); C23C 16/24 (2006.01); C23C 16/26 (2006.01); C23C 16/44 (2006.01); H01M 4/04 (2006.01); H01M 4/1395 (2010.01); H01M 4/36 (2006.01); H01M 4/38 (2006.01); H01M 4/62 (2006.01); H01M 4/02 (2006.01)

CPC H01M 4/0428 (2013.01) [C04B 35/528 (2013.01); C04B 35/62839 (2013.01); C04B 35/62884 (2013.01); C04B 35/62894 (2013.01); C23C 16/045 (2013.01); C23C 16/24 (2013.01); C23C 16/26 (2013.01); C23C 16/4417 (2013.01); H01M 4/1395 (2013.01); H01M 4/362 (2013.01); H01M 4/386 (2013.01); H01M 4/625 (2013.01); C04B 2235/422 (2013.01); C04B 2235/428 (2013.01); C04B 2235/5409 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/5445 (2013.01); H01M 2004/021 (2013.01); H01M 2004/027 (2013.01)]

41 Claims

1. A process for preparing silicon-containing composite particles, comprising the steps of:

(a) providing a plurality of porous particles having pores comprising micropores and/or mesopores, wherein:

(i) a D50 particle diameter of the porous particles is in the range from 0.5 to 200 μm;

(ii) a total pore volume of micropores and mesopores as measured by gas adsorption is in the range from 0.4 to 2.2 cm³/g;

(iii) a PD50 pore diameter of the porous particles as measured by gas adsorption is no more than 30 nm;

(b) combining a charge of the porous particles with a charge of a silicon-containing precursor in a batch pressure reactor, wherein the charge of the porous particles has a volume of at least 20 cm³per litre of reactor volume (cm³/L_RV), and wherein the charge of the silicon-containing precursor comprises at least 2 g of silicon per litre of reactor volume (g/L_RV); and

(c) heating the reactor to a temperature effective to cause deposition of silicon in the pores of the porous particles, thereby providing the silicon-containing composite particles.