A high capacity silicon–graphite composite as anode for lithium-ion batteries using low content amorphous silicon and compatible binders

In this study, silicon–graphite composites were prepared and investigated as anode materials for Li-ion batteries with small amounts of silicon and different binders. The silicon powders were prepared by ball-milling crystalline silicon for 100 h and 200 h. After 200 h, an average silicon particle size of 0.73 μm was obtained and XRD measurements confirmed the formation of an amorphous powder embedded within nanocrystalline regions. XPS analysis of the silicon samples showed that silicon particles were covered with a native silicon oxide layer that grows during ball-milling. Battery cycling of the silicon powders in half cells showed that the powder ball milled for 200 h gave the lowest first-cycle irreversible capacity and the highest reversible capacity reaching over 500 mA h g−1 after 50 cycles at C/12. Composites were made using graphite and only 5 wt% silicon powders. The silicon was found to be uniformly dispersed into the composites as evidenced by X-ray mapping and SEM. When tested in half cells using different binders, it was found that the polyetherimide binder showed the highest capacity reaching 514 mA h g−1 after 350 cycles at C/12, which is 1.6 times greater than commercial graphite anode. High rate cycling showed good capacity retention reaching half the capacity at 5 C.