Anodes and methods of making and use thereof

Abstract

Described herein are anodes and methods of making and use thereof. For example, disclosed are amorphous glasses, anodes comprising particles formed from these amorphous glasses, and electrochemical cells (e.g., batteries) including these anodes.

Description

[0001] ANODES AND METHODS OF MAKING AND USE THEREOF

[0002] CROSS-REFERENCE TO RELATED APPLICATION

[0003] This application claims priority to, and the benefit of, U.S. Provisional Application No. 63 / 538,352, filed on September 14, 2023, the content of which is hereby incorporated in its entirety.

[0004] BACKGROUND

[0005] Lithium-ion batteries are used in applications that need high energy or power densities. In addition to electronic portable equipment such as cellular phones, tablets, laptops and digital cameras, these density characteristics make them ideal for electric vehicles (EV). Typically, recharging these batteries takes much longer than refueling the average liquid-fueled vehicle. However, consumer demand will ultimately call for an electric refueling experience similar in duration to that of a liquid-fueled vehicle, i.e., less than 10 minutes. Likewise, faster charging for consumer portable electronics is desired.

[0006] Battery research and development over the last decade or more has focused on increasing the energy density of the battery cell via higher capacity materials and thicker electrodes. However, it is difficult for these thicker electrode systems to perform at higher charge rates. Degradation of thicker electrodes can occur more rapidly if charged too quickly when compared to thinner-coated electrodes. Slower charge rates are needed in order to allow the lithium-ions to reach all storage sites of the active material on the electrode. In general, the more storage sites per unit area a material has, the more time is required for those sites to accept lithium ions. Charging at too high of a rate runs the risk of exposing those materials to lithium ions at a rate they are unable to accept. This results in lithium plating on the surface of the anode, increased battery temperature, and other detrimental side chemical reactions that decrease life and performance characteristics.

[0007] During charging, lithium ions move from the cathode electrode and intercalate, or get inserted, into the anode electrode or react with the anode to form a stable structure. As the charge rate increases, lithium ions move from the cathode into the anode at a faster rate. At high charging rates, and typically at high state of charge (SOC), the lithium ions cannot move into the anode material because the available storage sites are filled or nearly filled and intercalation or the anode reaction slows down. As a result, lithium ions deposit, or plate, as lithium metal on the surface of the anode. Lithium plating can lead to dendrite growth, increases in resistance, and potentially a short circuit.

[0008] There are many anode chemistries with varying degrees of technology maturity. Carbonbased anodes such as graphite are some of the most prolific materials in the lithium-ion battery industry. However, when graphite is lithiated during recharge, the electrochemical potential of the electrode can become very low. Therefore, lithium plating can more easily occur, especially as the battery is charged at a fast rate and also as the battery approaches the fully charged state. Lithium titanate (LTO) possesses a higher potential and lower density when fully lithiated compared to graphite, suggesting that lithium plating is more difficult. LTO can be suitable for repeatedly and reliably charging at rates as high as IOC. New anode chemistries are currently being studied, but none have matured to a state of being viable candidates for extreme fast charging. For example, silicon offers advantages for fast charge in the form of reduced anode thickness due to very high areal capacity when compared with a graphite anode, but electrodes containing silicon for fast charge applications are still underdeveloped and of unknown viability.

[0009] State-of-the-art high-energy battery cell technology is capable of delivering 200 Wh / kg at 2C (30 minutes) charging. The main limitation is charging a graphite anode at rates higher than this can significantly degrade battery life and safety due to lithium plating and increased battery temperatures. The Department of Energy (DOE) has called for the next generation of fast charge battery cells, referred to as extreme fast charging, to be greater than 2 Ah, and to be capable of achieving 500 6C charge / lC discharge cycles with <20% fade in specific energy delivered (i.e., charge acceptance) from fast charge protocol, while achieving or improving state-of-the-art cell specific energy and cost. The charge rate does not need to be constant current, but the charge protocol must be finished within 10 minutes. The DOE's specification is for the charge protocol to deliver >180 Wh / kg of stored energy to the cell at the beginning of life (i.e., initial cell characterization testing). The energy delivered is determined by discharging a fast charged cell at the C / 3 rate to a defined minimum voltage. Upon completion of 500 6C charge* / lC discharge cycles the battery must have <20% fade in specific energy delivered from the fast charge protocol (i.e., >144 Wh / kg). There is thus a need to meet or exceed the specifications for a next generation extreme fast charging lithium ion battery.

[0010] Spray pyrolysis involves generation of nano to micron sized droplets from a precursor solution through either two-fluid atomization (liquid atomization by high velocity air) or ultrasonic atomization, droplet size shrinkage due to solvent evaporation, and conversion of precursor into solid particles. Spray pyrolysis allows for accurate control of material chemistry to trace levels. The size of particles generated through a fluid atomizer (nebulizer) depends on the gas and solution flow rates into and out of the atomizer or, in the case of ultrasonic atomization, the frequency applied to the nozzle. The concentration of dissolved solids and the time the particles spend in the hot zones of the furnace being used also play a big role in the size of particles generated.

[0011] Devices with improved properties are needed. The compositions, methods, and devices discussed herein addresses these and other needs.

[0012] SUMMARY

[0013] In accordance with the purposes of the disclosed compositions, methods, and devices as embodied and broadly described herein, the disclosed subject matter relates to anodes and methods of making and use thereof. For example, disclosed are amorphous glasses, anodes including particles formed from these amorphous glasses, and electrochemical cells (e.g., batteries) including these anodes.

[0014] Described herein are methods of making an anode including particles formed from an amorphous glass formed from a mixture including two or more active components and two or more amorphous forming components. In some embodiments, the method can include conducting spray pyrolysis including: aerosolizing an aqueous solution including an amorphous glass in a solvent to form amorphous glass droplets; evaporating the solvent in the amorphous glass droplets to form dried amorphous glass droplets; and calcining the dried amorphous glass droplets to form particles; collecting the particles; and forming the anode.

[0015] Described herein are methods of making a population of particles formed from an amorphous glass, the method including conducting spray pyrolysis including aerosolizing an aqueous solution including the amorphous glass in a solvent to form amorphous glass droplets; evaporating the solvent in the amorphous glass droplets to form dried amorphous glass droplets; and calcining the dried amorphous glass droplets to form the population of particles.

[0016] In some embodiments, the amorphous glass can include a glass defined by the formula below:

[0017] SixSny1AFMa2AFMb3AFMc4AFMd wherein

[0018] XAFM,2AFM,3AFM, and4AFM represent different elements, each chosen from iron, aluminum, titanium, copper, nickel, cobalt, manganese, gallium, indium, zirconium, and yttrium; x is from 50 to 90; y is from 1 to 40; a is from 0.5 to 20; b is from 0.5 to 15; c is from 0 to 10; and d is from 0 to 10.

[0019] Described herein are also anodes made by the methods described herein. Also described are electrochemical cells including the anode described herein, a cathode, and an electrolyte disposed between the anode and the cathode. In some embodiments, the electrochemical cell can include a lithium ion battery. Additional advantages of the disclosed compositions, devices, and methods will be set forth in part in the description which follows, and in part will be obvious from the description. The advantages of the disclosed compositions, devices, and methods will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosed devices and methods, as claimed.

[0020] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

[0021] DETAILED DESCRIPTION

[0022] The compositions, methods, and devices described herein may be understood more readily by reference to the following detailed description of specific aspects of the disclosed subject matter and the Examples included therein.

[0023] Before the present compositions, methods, and devices are disclosed and described, it is to be understood that the aspects described below are not limited to specific synthetic methods or specific reagents, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0024] Also, throughout this specification, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which the disclosed matter pertains. The references disclosed are also individually and specifically incorporated by reference herein for the material contained in them that is discussed in the sentence in which the reference is relied upon.

[0025] In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings.

[0026] Throughout the description and claims of this specification the word “comprise” and other forms of the word, such as “comprising” and “comprises,” means including but not limited to, and is not intended to exclude, for example, other additives, components, integers, or steps.

[0027] As used in the description and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a composition” includes mixtures of two or more such compositions, reference to “an agent” includes mixtures of two or more such agents, reference to “the component” includes mixtures of two or more such components, and the like.

[0028] “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.

[0029] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. By “about” is meant within 5% of the value, e.g., within 4, 3, 2, or 1% of the value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0030] Values can be expressed herein as an “average” value. “Average” generally refers to the statistical mean value.

[0031] By “substantially” is meant within 5%, e.g., within 4%, 3%, 2%, or 1%.

[0032] “Exemplary” means “an example of’ and is not intended to convey an indication of a preferred or ideal embodiment. “Such as” is not used in a restrictive sense, but for explanatory purposes.

[0033] It is understood that throughout this specification the identifiers “first” and “second” are used solely to aid in distinguishing the various components and steps of the disclosed subject matter. The identifiers “first” and “second” are not intended to imply any particular order, amount, preference, or importance to the components or steps modified by these terms. References in the specification and concluding claims to parts by weight of a particular element or component in a composition denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a compound containing 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the compound.

[0034] A weight percent (wt. %) of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.

[0035] The term “or combinations thereof’ as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof’ is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CAB ABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

[0036] As used herein, the terms “active component” and “active material” are used synonymously, and refer to a material that reacts with a working ion (e.g., lithium) under conditions typically encountered during charging and discharging of a battery (e.g., a lithium ion battery). Two or more active components can be present as the majority components of the amorphous glasses described herein.

[0037] As used herein, the terms “inactive component” and “inactive material” are used synonymously, and refer to a material that does not react with a working ion (e.g., lithium) under conditions typically encountered during charging and discharging of a battery (e.g., a lithium ion battery). Two or more inactive components can be present as minority components of the amorphous glasses described herein.

[0038] As used herein, the term “metal” refers to both metals and metalloids such as silicon and germanium. The metal is often in an elemental state.

[0039] As used herein, the term “lithiation” refers to the process of adding lithium to an amorphous glass described herein (i.e., lithium ions are reduced). Likewise, the term “sodiation” refers to an analogous process where sodium is added to an amorphous glass described herein.

[0040] As used herein, the term “delithiation” refers to the process of removing lithium from an amorphous glass described herein (i.e., lithium ions are oxidized). Likewise, the term “desodiation” refers to an analogous process where sodium is removed from an amorphous glass described herein.

[0041] As used herein, the term “charging” refers to a process of providing electrochemical energy to a battery.

[0042] As used herein, the term “discharging” refers to a process of removing electrochemical energy from a battery (i.e., discharging is a process of using the battery to do useful work).

[0043] As used herein, the term “cathode” refers to the electrode where electrochemical reduction occurs during the discharging process. During discharging, the cathode undergoes lithiation. During charging, lithium atoms are removed from this electrode.

[0044] As used herein, the term “anode” refers to the electrode where electrochemical oxidation occurs during the discharging process. During discharging, the anode undergoes delithiation. During charging, lithium atoms are added to this electrode.

[0045] Anodes and methods of making and use thereof

[0046] Described herein are anodes and methods of making and use thereof. For example, disclosed herein are methods of making anodes using spray pyrolysis. For example, disclosed herein are methods of making particles and / or anodes including the compositions described in PCT / US2019 / 044759 (corresponding U.S. Patent Application No. 2021 / 0305557), which is hereby incorporated herein by reference for its description thereof, using spray pyrolysis.

[0047] For example, described herein are methods of making an anode including particles formed from an amorphous glass, the method including spray pyrolysis. The amorphous glass can be formed from a mixture including two or more active components and two or more amorphous forming components. In some examples, the methods can include spray pyrolysis of the mixture including two or more active components and two or more amorphous forming components.Described herein are methods of making an anode including particles formed from an amorphous glass formed from a mixture including two or more active components and two or more amorphous forming components. In some embodiments, the method can include conducting spray pyrolysis including aerosolizing an aqueous solution including an amorphous glass in a solvent to form amorphous glass droplets; evaporating the solvent in the amorphous glass droplets to form dried amorphous glass droplets; calcining the dried amorphous glass droplets to form particles; collecting the particles; and forming the anode.

[0048] In some embodiments, the aqueous solution can include from 5% to 30% amorphous glass, from 10%-50% solvent, and from 5%-30% acids. In some embodiments, the amorphous glass can be present in the aqueous solution in a concentration of from 5% to 30% amorphous glass (e.g., from 5% to 10%, from 5% to 15%, from 5% to 20%, from 5% to 25%, from 10% to 15%, from 10% to 20%, from 10% to 25%, from 10% to 30%, from 15% to 20%, from 15% to 25%, from 15% to 30%, from 20% to 25%, from 20% to 30%, or from 25% to 30%).

[0049] In some embodiments, the solvent can be present in the aqueous solution in a concentration of from 10%-50% solvent (e.g., from 10% to 20%, from 10% to 25%, from 10% to 30%, from 10% to 35%, from 10% to 40%, from 10% to 45%, from 15% to 20%, from 15% to 25%, from 15% to 30%, from 15% to 35%, from 15% to 40%, from 15% to 45%, from 15% to 50%, from 20% to 25%, from 20% to 30%, from 20% to 35%, from 20% to 40%, from 20% to 45%, from 20% to 50%, from 25% to 30%, from 25% to 35%, from 25% to 40%, from 25% to 45%, from 25% to 50%, from 30% to 35%, from 30% to 40%, from 30% to 45%, from 30% to 50%, from 35% to 40%, from 35% to 45%, from 35% to 50%, from 40% to 45%, from 40% to 50%, or from 45% to 50%).

[0050] In some embodiments, the acid be present in the aqueous solution in a concentration of from 5%-30% acids (e.g., from 5% to 10%, from 5% to 15%, from 5% to 20%, from 5% to 25%, from 10% to 15%, from 10% to 20%, from 10% to 25%, from 10% to 30%, from 15% to 20%, from 15% to 25%, from 15% to 30%, from 20% to 25%, from 20% to 30%, or from 25% to 30%).

[0051] In some embodiments, the aqueous solution can preferably include 16% amorphous glass, 30% solvent, and 12% acids.

[0052] In some embodiments, the solvent can include, but is not limited to N,N- Dimethylformamide (DMF), dichloromethane (DCM), 2-methyltetrahydrofuran (Methyl THF), isopropanol, 1-propanol, ethanol, or methanol. In some embodiments, the solvent can be DMF.

[0053] The anode described herein can be obtained by pyrolysis performed simultaneously with spraying (spray pyrolysis) of an aqueous solution. In some embodiments, the aqueous solution includes an amorphouse glass. In some embodiments, the amorphous glass can be formed from a mixture including two or more active components and two or more amorphous forming components

[0054] The conditions for spray pyrolysis are not particularly limited, and in accordance with a spray drying machine, a spray method, and the like, a spray pressure, a spray amount, a drying temperature, and the like can be appropriately selected. Drying and pyrolysis may also be simultaneously performed by allowing liquid droplets prepared immediately after spraying to pass through a heating tube. After a solution is sprayed by a nozzle similar to that of a spray drying machine to form fine liquid droplets, the liquid droplets are allowed to pass through a heated tube for a predetermined time for carbonization, and a carbonized product obtained thereby is collected by a cyclone or the like. For example, when spray is performed by a nozzle method using a spray pyrolysis apparatus, the spray pressure, the spray inlet temperature, the heating time, and the heating temperature may be set to 0.01 to 1 MPa, 30° C to 300° C, 1 to 10 seconds, and 30° C to 1,500° C, respectively.

[0055] The pyrolysis can be performed by a related known method and is not particularly limited, and for example, after the temperature is increased at approximately 5° C per one minute in an inert gas atmosphere, pyrolysis can be performed at the following temperature from 500° C to 1,500° C (e.g., from 500° C to 1,400° C, from 500° C to 1,300° C, from 500° C to 1,200° C, from 500° C to 1,100° C, from 500° C to 1,000° C, from 500° C to 900° C, from 500° C to 800° C, from 500° C to 700° C, from 500° C to 600° C, from 600° C to 1,500° C, from 600° C to 1,400° C, from 600° C to 1,300° C, from 600° C to 1,200° C, from 600° C to 1,100° C, from 600° C to 1,000° C, from 600° C to 900° C, from 600° C to 800° C, from 600° C to 700° C, from 700° C to 1,500° C, from 700° C to 1,400° C, from 700° C to 1,300° C, from 700° C to 1,200° C, from 700° C to 1,100° C, from 700° C to 1,000° C, from 700° C to 900° C, from 700° C to 800° C, from 800° C to 1,500° C, from 800° C to 1,400° C, from 800° C to 1,300° C, from 800° C to 1,200° C, from 800° C to 1,100° C, from 800° C to 1,000° C, from 800° C to 900° C, from 1000° C to 1,500° C, from 1000° C to 1,400° C, from 1000° C to 1,300° C, from 1000° C to 1,200° C, from 1000° C to 1,100° C, from 1200° C to 1,500° C, from 1200° C to 1,400° C, or from 1200° C to 1,300° C).

[0056] As the inert gas can include, but are not limited to nitrogen, helium, and argon. In addition, in this inert gas, a reducing gas, such as a hydrogen gas, may also be included.

[0057] In addition, this pyrolysis step may be performed through at least two stages. That is, at the first stage, pyrolysis is performed for a predetermined time at a temperature lower than the final reaching temperature, and pyrolysis can be again performed by increasing the temperature.

[0058] The heat treatment described above may be performed by either a fixed bed method or a fluid bed method, and a heating method of a carbonizing furnace and the type thereof are not particularly limited as long as a furnace having a function to perform heating to a predetermined temperature is used. As the carbonizing furnace, for example, a Riedhammer furnace, a tunnel furnace, or a single furnace may be used. The particle size and particle size distribution of the particles can vary. The particles can have any suitable shape or combination of shapes. For example, the particles can have an oblate shape, a prolate shape, a bladed shape, an equant shape, or a combination thereof. In some examples, the particles can be non-fibrous. Elongate particles and fibers can be characterized in terms of their aspect ratio. “Aspect ratio,” as used herein, refers to the length divided by the diameter of a particle or fiber. In some examples, the particles can have an aspect ratio of 10 or less, such as an aspect ratio of 5 or less or an aspect ratio of 2 or less. In some examples, the particles can be substantially spherical in shape.

[0059] The population of particles can have an average particle size. “Average particle size” and “mean particle size” are used interchangeably herein, and generally refer to the statistical mean particle size of the particles in a population of particles. For a particle with a substantially spherical shape, the diameter of a particle can refer, for example, to the hydrodynamic diameter. As used herein, the hydrodynamic diameter of a particle can refer to the largest linear distance between two points on the surface of the particle. For particles having non-spherical shapes, the diameter of a particle can refer, for example, to the smallest cross-sectional dimension of the particle (i.e., the smallest linear distance passing through the center of the particle and intersecting two points on the surface of the particle). Mean particle size can be measured using methods known in the art, such as evaluation by scanning electron microscopy (SEM), transmission electron microscopy, and / or dynamic light scattering.

[0060] In some examples, the particles can include a population of microparticles. For example, In some examples, the particles can include a population of microparticles having an average particle size of at least 1 micron (e.g., at least 2 microns, at least 3 microns, at least 4 microns, at least 5 microns, at least 6 microns, at least 7 microns, at least 8 microns, at least 9 microns, at least 10 microns, at least 11 microns, at least 12 microns, at least 13 microns, or at least 14 microns), as determined by SEM. In some examples, the particles can include a population of microparticles having an average particle size of 15 microns or less (e.g., 14 microns or less, 13 microns or less, 12 microns or less, 11 microns or less, 10 microns or less, 9 microns or less, 8 microns or less, 7 microns or less, 6 microns or less, 5 microns or less, 4 microns or less, 3 microns or less, or 2 microns or less), as determined by SEM.

[0061] The particles can include a population of microparticles having an average particle size ranging from any of the minimum values described above to any of the maximum values described above. For example, in some examples, the particles can include a population of microparticles having an average particle size of from 1 micron to 15 microns (e.g., from 1 micron to 5 microns), as determined by SEM.

[0062] In some examples, the particles can include a population of nanoparticles. For example, In some examples, the particles can include a population of nanoparticles having an average particle size of at least 25 nm (e.g., at least 50 nm, at least 100 nm, at least 150 nm, at least 200 nm, at least 250 nm, at least 300 nm, at least 350 nm, at least 400 nm, at least 450 nm, at least 500 nm, at least 550 nm, at least 600 nm, at least 650 nm, at least 700 nm, at least 750 nm, at least 800 nm, at least 850 nm, at least 900 nm, or at least 950 nm), as determined by SEM. In some examples, the particles can include a population of nanoparticles having an average particle size of less than 1 micron (e.g., 950 nm or less, 900 nm or less, 850 nm or less, 800 nm or less, 750 nm or less, 700 nm or less, 650 nm or less, 600 nm or less, 550 nm or less, 500 nm or less, 450 nm or less, 400 nm or less, 350 nm or less, 300 nm or less, 250 nm or less, 200 nm or less, 150 nm or less, 100 nm or less, or 50 nm or less), as determined by SEM.

[0063] The particles can include a population of nanoparticles having an average particle size ranging from any of the minimum values described above to any of the maximum values described above. For example, In some examples, the particles can include a population of microparticles having an average particle size of from 25 nm to less than 1 micron (e.g., from 25 nm to 200 nm or from 100 nm to 750 nm), as determined by SEM.

[0064] In some examples, the population of particles is a monodisperse population of particles. In some examples, the population of particles is a polydisperse population of particles. In some instances where the population of particles is monodisperse, greater that 50% of the particle size distribution, more preferably 60% of the particle size distribution, most preferably 75% of the particle size distribution lies within 10% of the median particle size.

[0065] In some examples, the two or more active components can include at least 51 mol % (e.g., at least 55 mol %, at least 60 mol %, at least 65 mol %, at least 70 mol %, at least 75 mol %, at least 80 mol %, at least 85 mol %, at least 90 mol %, or at least 95 mol %) of the amorphous glass. In some examples, the two or more active components can include 99 mol % or less (e.g., 95 mol % or less, 90 mol % or less, 85 mol % or less, 80 mol % or less, 75 mol % or less, 70 mol % or less, 65 mol % or less, 60 mol % or less, or 55 mol % or less).

[0066] The two or more active components can be present in the amorphous glass in an amount ranging from any of the minimum values described above to any of the maximum values described above. For example, In some examples, the two or more active components can include from 51 mol % to 99 mol % (e.g., from 80 mol % to 95 mol % of the amorphous glass. In some examples, the two or more amorphous forming components can include at least 1 mol % (e.g., at least 5 mol %, at least 10 mol %, at least 15 mol %, at least 20 mol %, at least 25 mol %, at least 30 mol %, at least 35 mol %, at least 40 mol %, or at least 45 mol %) of the amorphous glass. In some examples, the two or more amorphous forming components can include 49 mol % or less (e.g., 45 mol % or less, 40 mol % or less, 35 mol % or less, 30 mol % or less, 35 mol % or less, 20 mol % or less, 25 mol % or less, 10 mol % or less, or 5 mol % or less).

[0067] The two or more amorphous forming components can be present in the amorphous glass in an amount ranging from any of the minimum values described above to any of the maximum values described above. For example, In some examples, the two or more amorphous forming components can include from 1 mol % to 49 mol % (e.g., from 5 mol % to 25 mol %, or from 5 mol % to 20 mol %) of the amorphous glass.

[0068] The two or more active components and the two or more amorphous forming components can be present in the amorphous glass at a molar ratio of from 1.1 : 1 to 50: 1, such as from 1.1 : 1 to 25: 1, from 2: 1 to 25: 1, from 2: 1 to 20: 1, from 4: 1 to 20: 1, from 5: 1 to 15: 1, or from 5: 1 to 10: 1.

[0069] The two or more active components can include silicon, tin, lead, antimony, germanium, gallium, indium, bismuth, or any combination thereof. In some examples, the two or more active components can include silicon, tin, antimony, germanium, or any combination thereof. In some examples, the two or more active components can include silicon. In some examples, the two or more active components can include tin.

[0070] In some examples, the amorphous glass can include a SiSn-based glass (e.g., a glass that includes silicon, tin, optionally one or more additional active components, and two or more amorphous forming components). In the case of SiSn-based amorphous glasses, the two or more active components include silicon and tin, and the silicon and the tin can be present a molar ratio of from 1.1 : 1 to 20: 1 (e.g., from 2: 1 to 15: 1 or from 3: 1 to 12: 1).

[0071] The two or more amorphous forming components can include electrochemically inactive components that favor glass formation. In some examples, suitable amorphous forming components can include, but are not limited to, transition metals, rare earth metals, or a combination thereof. Examples of suitable amorphous forming components include iron, aluminum, titanium, copper, nickel, cobalt, manganese, zirconium, yttrium, boron, niobium, molybdenum, tungsten, or any combination thereof. Other possible amorphous forming components can include chromium, tantalum, lanthanum, cerium, and Misch metal (i.e., a mixture of rare earth metals).

[0072] In some examples, the two or more amorphous forming components can include one or more lanthanides. For example, the one or more lanthanides include from 1 mol % to 25 mol % (e.g., from 5 mol % to 20 mol % or from 10 mol % to 20 mol %) of the amorphous glass.

[0073] In some examples, the two or more amorphous forming components can include one or more Group 4 elements. For example, the one or more Group 4 elements can include from 1 mol % to 15 mol % (e.g., from 1 mol % to 10 mol % or from 2 mol % to 8 mol %) of the amorphous glass.

[0074] In some examples, the two or more amorphous forming components include one or more Group 13 elements. For example, the one or more Group 13 elements can include from 1 mol % to 8 mol % (e.g., from 2 mol % to 6 mol % or from 3 mol % to 4 mol %) of the amorphous glass.

[0075] In some examples, the amorphous glass includes a glass defined by the formula below: SixSny1AFMa2AFMb3AFMc4AFMd wherein1AFM,2AFM,3AFM, and4AFM represent different elements, each chosen from iron, aluminum, titanium, copper, nickel, cobalt, manganese, gallium, indium, zirconium, and yttrium; x is from 50 to 90; y is from 1 to 40; a is from 0.5 to 20; b is from 0.5 to 15; c is from 0 to 10; and d is from 0 to 10.

[0076] In some examples, x can be at least 50 (e.g., at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, or at least 85). In some examples, x can be 90 or less (e.g., 85 or less, 80 or less, 75 or less, 70 or less, 65 or less, 60 or less, or 55 or less).

[0077] In some examples, x can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, x can be from 50 to 90 (e.g., from 60 to 80).

[0078] In some examples, y can be at least 1 (e.g., at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, or at least 35). In some examples, y can be 40 or less (e.g., 35 or less, 30 or less, 25 or less, 20 or less, 15 or less, 10 or less, or 5 or less).

[0079] In some examples, y can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, y can be from 1 to 40 (e.g., from 5 to 20).

[0080] In some examples, a can be at least 0.5 (e.g., at least 1, at least 2.5, at least 5, at least 7.5, at least 10, or at least 15). In some examples, a can be 20 or less (e.g., 15 or less, 10 or less, 7.5 or less, 5 or less, 2.5 or less, or 1 or less). In some examples, a can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, a can be from 0.5 to 20 (e.g., from 2.5 to 15).

[0081] In some examples, b can be at least 0.5 (e.g., at least 1, at least 2.5, at least 5, at least 7.5, or at least 10). In some examples, b can be 15 or less (e.g., 10 or less, 7.5 or less, 5 or less, 2.5 or less, or 1 or less).

[0082] In some examples, b can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, b can be from 0.5 to 15 (e.g., from 2.5 to 10).

[0083] In some examples, c can be greater than 0 (e.g., at least 0.5, at least 1, at least 2.5, at least 5, or at least 7.5). In some examples, c can be 10 or less (e.g., 7.5 or less, 5 or less, 2.5 or less, 1 or less, or 0.5 or less).

[0084] In some examples, c can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, c can be from 0 to 10 (e.g., from 2.5 to 7.5).

[0085] In some examples, d can be greater than 0 (e.g., at least 0.5, at least 1, at least 2.5, at least 5, or at least 7.5). In some examples, d can be 10 or less (e.g., 7.5 or less, 5 or less, 2.5 or less, 1 or less, or 0.5 or less).

[0086] In some examples, d can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, d can be from 0 to 10 (e.g., from 2.5 to 7.5).

[0087] In some examples, the amorphous glass can include a SiSnCeFeAlTi glass (e.g., SieoSnnCeisFesAhTi?).

[0088] In some examples, the amorphous glass can include a SiSnFeAlTi glass (e.g., SivsSmsFeeAhTi?).

[0089] In some examples, the amorphous glass can include a SiSnAlTi glass (e.g., SivsSmeAhTi?).

[0090] Optionally, in some examples, the particles can further include a carbonaceous material disposed on a surface of the particles.

[0091] In some examples, the particles can further include a carbonaceous material (e.g., residue from the pyrolysis of a polymeric template in which the particles were formed).

[0092] The particles (formed from an amorphous glass) described herein can be dispersed in any suitable binder material to form an anode. In some examples, the binder can include a polymeric binder. The polymeric binder can include a conductive polymer, a non-conductive polymer, or a combination thereof. In some examples, the anode can include particles described herein dispersed in an elastomeric polymer binder. Suitable elastomeric polymer binders include polyolefins such as those prepared from ethylene, propylene, or butylene monomers; polyanilines; fluorinated polyolefins such as those prepared from vinylidene fluoride monomers; perfluorinated polyolefins such as those prepared from hexafluoropropylene monomer; perfluorinated poly(alkyl vinyl ethers); perfluorinated poly(alkoxy vinyl ethers); or combinations thereof. Specific examples of elastomeric polymer binders include terpolymers of vinylidene fluoride (PVDF), tetrafluoroethylene, and propylene; and copolymers of vinylidene fluoride and hexafluoropropylene. Commercially available fluorinated elastomers include those sold by Dyneon, LLC, Oakdale, Minn, under the trade designation “FC-2178”, “FC-2179”, and “BRE- 73 IX”.

[0093] In some examples, the binder can include a polymeric binder such as vinylidene fluoride (PVDF), polyaniline, or a combination thereof. In some examples, the polymeric binder can include a conductive polymer.

[0094] If desired for the construction of a particular anode, the binder can be crosslinked. Crosslinking can improve the mechanical properties of the polymer and / or can improve the contact between the particles and any electrically conductive diluent that may be present.

[0095] Optionally, an electrically conductive diluent can be added to facilitate electron transfer from the particles to a current collector. Examples of electrically conductive diluents include, but are not limited to, carbon, metal, metal nitrides, metal carbides, metal silicides, and metal borides. In some anodes, the electrically conductive diluents can be carbon blacks such as those commercially available from MMM Carbon of Belgium under the trade designation “SUPER P” and “SUPER S” and from Chevron Chemical Co. of Houston, Tex. under the trade designation “SHAWANIGAN BLACK”; acetylene black; furnace black; lamp black; graphite; carbon fibers; or combinations thereof. In some examples, the binder can include a carbonaceous material such as carbon black.

[0096] The anode can further include an adhesion promoter that promotes adhesion of the particles and the electrically conductive diluent to the polymer binder. The combination of an adhesion promoter and polymer binder accommodates, at least partially, volume changes that may occur in the alloy composition during repeated cycles of lithiation and delithiation. The adhesion promoter can be part of the binder (e.g., in the form of a functional group) or can be in the form a coating on the alloy composition, the electrically conductive diluent, or a combination thereof. Examples of adhesion promoters include, but are not limited to, silanes, titanates, and phosphonates as described in U.S. Patent Application 2003 / 0058240, the disclosure of which is incorporated herein by reference.

[0097] Described herein are also anodes made by the methods described herein. Also described are electrochemical cells including the anode described herein, a cathode, and an electrolyte disposed between the anode and the cathode. In some embodiments, the electrochemical cell can include a lithium ion battery. In some examples, the electrochemical cell can include a lithium ion battery, and the cathode includes a lithium-based cathode (e.g., lithium iron phosphate, LiNii-xMnx / 2Cox / 2O2, wherein x = 0.4 or 0.2, or LiNi0.8Co0.15Al0.05O2).

[0098] Any suitable electrolyte can be included in the lithium ion battery. The electrolyte can be in the form of a solid or liquid. Exemplary solid electrolytes include polymeric electrolytes such as polyethylene oxide, polytetrafluoroethylene, polyvinylidene fluoride, fluorine-containing copolymers, polyacrylonitrile, or combinations thereof. Exemplary liquid electrolytes include ethylene carbonate, dimethyl carbonate, diethyl carbonate, propylene carbonate, gammabutyrolactone, tetrahydrofuran, 1,2-dimethoxy ethane, di oxolane, or combinations thereof. The electrolyte includes a lithium electrolyte salt such as LiPFe, LiBF4, LiCICh, LiN(SO2CF3)2, LiN(SO2CF2CF3)2, and the like.

[0099] The electrolyte can include a redox shuttle molecule, an electrochemically reversible material that during charging can become oxidized at the cathode, migrate to the anode where it can become reduced to reform the unoxidized (or less-oxidized) shuttle species, and migrate back to the cathode. Suitable redox shuttle molecules include, for example, those described in U.S. Pat. Nos. 5,709,968 (Shimizu), U.S. Pat. No. 5,763,119 (Adachi), U.S. Pat. No. 5,536,599 (Alamgir et al.), U.S. Pat. No. 5,858,573 (Abraham et al.), U.S. Pat. No. 5,882,812 (Visco et al.), U.S. Pat. No. 6,004,698 (Richardson et al.), U.S. Pat. No. 6,045,952 (Kerr et al.), and U.S. Pat. No. 6,387,571 Bl (Lain et al.); and in PCT Published Patent Application No. WO 01 / 29920 Al (Richardson et al.).

[0100] Any suitable cathode known for use in lithium ion batteries can be utilized. Some exemplary cathodes in a charged state contain lithium atoms intercalated within a lithium transition metal oxide such as lithium cobalt dioxide, lithium nickel dioxide, and lithium manganese dioxide. Other exemplary cathodes are those disclosed in U.S. Pat. No. 6,680,145 B2 (Obrovac et al.), incorporated herein by reference. That is, the cathode can contain particles that include transition metal grains (e.g., iron, cobalt, chromium, nickel, vanadium, manganese, copper, zinc, zirconium, molybdenum, niobium, or combinations thereof) having a grain size no greater than about 50 nanometers in combination with lithium-containing grains selected from lithium oxides, lithium sulfides, lithium halides (e.g., chlorides, bromides, iodides, or fluorides), or combinations thereof. These particles can be used alone or in combination with a lithium- transition metal oxide material such as lithium cobalt dioxide.

[0101] In some lithium ion batteries with solid electrolytes, the cathode can include LiVsOs or LiV2Os. In other lithium ion batteries with liquid electrolytes, the cathode can include LiCoCh, LiCoo.2Nio.8O2, LiMn2O4, LiFePO4, or LiNiO2.

[0102] The lithium ion batteries can be used as a power supply in a variety of applications. For example, the lithium ion batteries can be used in power supplies for electronic devices such as computers and various hand-held devices, motor vehicles, power tools, photographic equipment, and telecommunication devices. Multiple lithium ion batteries can be combined to provide a battery pack.

[0103] In some examples, the electrochemical cell can exhibit an energy density of at least 180 Wh / kg at room temperature.

[0104] In some examples, the electrochemical cell can exhibit a charge rate of from 1 minute to 10 minutes to 30% of a state of charge (SOC), a charge rate of from 1 minute to 10 minutes to 50% of a state of charge (SOC), a charge rate of from 1 minute to 10 minutes to 70% of a state of charge (SOC), and / or a charge rate of from 1 minute to 10 minutes to 90% of a state of charge (SOC).

[0105] Also provided are methods of making populations of particles formed from an amorphous glass, the methods including spray pyrolysis. The amorphous glass can include a glass defined by the formula below:

[0106] SixSny1AFMa2AFMb3AFMc4AFMd wherein1AFM,2AFM,3AFM, and4AFM represent different elements, each chosen from iron, aluminum, titanium, copper, nickel, cobalt, manganese, gallium, indium, zirconium, and yttrium; x is from 50 to 90; y is from 1 to 40; a is from 0.5 to 20; b is from 0.5 to 15; c is from 0 to 10; and d is from 0 to 10.

[0107] In some examples, x can be at least 50 (e.g., at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, or at least 85). In some examples, x can be 90 or less (e.g., 85 or less, 80 or less, 75 or less, 70 or less, 65 or less, 60 or less, or 55 or less).

[0108] In some examples, x can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, x can be from 50 to 90 (e.g., from 60 to 80). In some examples, y can be at least 1 (e.g., at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, or at least 35). In some examples, y can be 40 or less (e.g., 35 or less, 30 or less, 25 or less, 20 or less, 15 or less, 10 or less, or 5 or less).

[0109] In some examples, y can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, y can be from 1 to 40 (e.g., from 5 to 20).

[0110] In some examples, a can be at least 0.5 (e.g., at least 1, at least 2.5, at least 5, at least 7.5, at least 10, or at least 15). In some examples, a can be 20 or less (e.g., 15 or less, 10 or less, 7.5 or less, 5 or less, 2.5 or less, or 1 or less).

[0111] In some examples, a can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, a can be from 0.5 to 20 (e.g., from 2.5 to 15).

[0112] In some examples, b can be at least 0.5 (e.g., at least 1, at least 2.5, at least 5, at least 7.5, or at least 10). In some examples, b can be 15 or less (e.g., 10 or less, 7.5 or less, 5 or less, 2.5 or less, or 1 or less).

[0113] In some examples, b can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, b can be from 0.5 to 15 (e.g., from 2.5 to 10).

[0114] In some examples, c can be greater than 0 (e.g., at least 0.5, at least 1, at least 2.5, at least 5, or at least 7.5). In some examples, c can be 10 or less (e.g., 7.5 or less, 5 or less, 2.5 or less, 1 or less, or 0.5 or less).

[0115] In some examples, c can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, c can be from 0 to 10 (e.g., from 2.5 to 7.5).

[0116] In some examples, d can be greater than 0 (e.g., at least 0.5, at least 1, at least 2.5, at least 5, or at least 7.5). In some examples, d can be 10 or less (e.g., 7.5 or less, 5 or less, 2.5 or less, 1 or less, or 0.5 or less).

[0117] In some examples, d can range from any of the minimum values described above to any of the maximum values described above. For example, In some examples, d can be from 0 to 10 (e.g., from 2.5 to 7.5).

[0118] In some examples, the amorphous glass can include a SiSnCeFeAlTi glass (e.g., SieoSnnCeisFesAhTi?). In some examples, the amorphous glass can include a SiSnFeAlTi glass (e.g., SiTsSmsFeeAhTi?).

[0119] In some examples, the amorphous glass can include a SiSnAlTi glass (e.g., SiTsSnieAUTi?).

[0120] The particle size and particle size distribution of the particles can vary. In some examples, the particles can have an aspect ratio of 10 or less, such as an aspect ratio of 5 or less or an aspect ratio of 2 or less. In some examples, the particles can be substantially spherical in shape.

[0121] In some examples, the particles include a monodisperse population of particles.

[0122] In some examples, the particles can include a population of microparticles. For example, In some examples, the particles can include a population of microparticles can have an average particle size of from 1 micron to 15 microns (e.g., from 1 micron to 5 microns), as determined by scanning electron microscopy (SEM). In some examples, the particles can include a population of nanoparticles. For example, In some examples, the population of nanoparticles has an average particle size of from 25 nm to less than 1 micron (e.g., from 25 nm to 200 nm or from 100 nm to 750 nm), as determined by scanning electron microscopy (SEM).

[0123] The two or more active components can include from 51 mol % to 99 mol % (e.g., from 80 mol % to 95 mol % of the amorphous glass. The two or more amorphous forming components can include from 1 mol % to 49 mol % (e.g., from 5 mol % to 25 mol %, or from 5 mol % to 20 mol %) of the amorphous glass. The two or more active components and the two or more amorphous forming components can be present in the amorphous glass at a molar ratio of from 1.1 : 1 to 50: 1, such as from 1.1 : 1 to 25: 1, from 2: 1 to 25: 1, from 2: 1 to 20: 1, from 4: 1 to 20: 1, from 5: 1 to 15: 1, or from 5: 1 to 10: 1.

[0124] Also described herein are anodes including any of the particles made by any of the methods described herein.

[0125] Also described herein are anodes made by any of the methods described herein.

[0126] Also described herein are methods of use of any of anodes made by any of the methods described herein, for example in a device, a system, and / or an article.

[0127] For example, also described herein are devices, such as a battery, including any of the anodes made by any of the methods disclosed herein.

[0128] Also described herein are batteries including an anode made by any of the methods described herein. In some examples, the battery exhibits a capacity retention of 80% or more (e.g., 90% or more) for 10 cycles or more (e.g., 25 cycles or more, 50 cycles or more, or 100 cycles or more).

[0129] Also described herein are systems including one or more of the batteries disclosed herein. For example, the system can be an energy storage system.

[0130] Also described herein are articles (e.g., articles of manufacture) including one or more of the batteries disclosed herein. For example, the article can be a vehicle, such as a hybrid electric vehicle or an all-electric vehicle. In some examples, the article can include an electronic device, such as a portable electronic device, a laptop, a watch, a cell phone, etc.

[0131] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.

[0132] The examples below are intended to further illustrate certain aspects of the devices and methods described herein, and are not intended to limit the scope of the claims.

[0133] EXAMPLES

[0134] The following examples are set forth below to illustrate the methods and results according to the disclosed subject matter. These examples are not intended to be inclusive of all aspects of the subject matter disclosed herein, but rather to illustrate representative methods and results. These examples are not intended to exclude equivalents and variations of the present invention which are apparent to one skilled in the art.

[0135] Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.) but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in °C or is at ambient temperature, and pressure is at or near atmospheric. There are numerous variations and combinations of measurement conditions, e.g., component concentrations, temperatures, pressures and other measurement ranges and conditions that can be used to optimize the described process.

[0136] Example 1 - Anode synthesis using spray pyrolysis

[0137] Described herein are methods of making anodes using spray pyrolysis.

[0138] Spray pyrolysis involves generation of nano to micron sized droplets from a precursor solution through either two-fluid atomization (liquid atomization by high velocity air) or ultrasonic atomization, droplet size shrinkage due to solvent evaporation, and conversion of precursor into solid particles.

[0139] The size of particles generated through a fluid atomizer (nebulizer) depends on the gas and solution flow rates into and out of the atomizer or, in the case of ultrasonic atomization, the frequency applied to the nozzle. The concentration of dissolved solids and the time the particles spend in the hot zones of the furnace being used also play a big role in the size of particles generated.

[0140] Nanoparticle synthesis by ultrasonic spray pyrolysis is described, for example, by Tsai et al. Journal of Materials Science, 2004, 39, 3647-3657, which is hereby incorporated herein by reference for its description thereof.

[0141] For example, the anode can be made using spray pyrolysis of an aqueous solution including 16% dissolved solids, 30% DMF, and 12% acids.

[0142] Other advantages which are obvious and which are inherent to the invention will be evident to one skilled in the art. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

[0143] The methods of the appended claims are not limited in scope by the specific methods described herein, which are intended as illustrations of a few aspects of the claims and any methods that are functionally equivalent are intended to fall within the scope of the claims. Various modifications of the methods in addition to those shown and described herein are intended to fall within the scope of the appended claims. Further, while only certain representative method steps disclosed herein are specifically described, other combinations of the method steps also are intended to fall within the scope of the appended claims, even if not specifically recited. Thus, a combination of steps, elements, components, or constituents may be explicitly mentioned herein or less, however, other combinations of steps, elements, components, and constituents are included, even though not explicitly stated.

Claims

CLAIMSWhat is claimed is:

1. A method of making an anode comprising particles formed from an amorphous glass formed from a mixture comprising two or more active components and two or more amorphous forming components, the method comprising spray pyrolysis; optionally wherein the spray pyrolysis comprises: aerosolizing an aqueous solution comprising an amorphous glass in a solvent to form amorphous glass droplets; evaporating the solvent in the amorphous glass droplets to form dried amorphous glass droplets; and calcining the dried amorphous glass droplets to form particles; optionally wherein the method further comprises collecting the particles and forming the anode.

2. The method of claim 1, wherein the particles comprise a population of microparticles.

3. The method of claim 2, wherein the population of microparticles has an average particle size of from 1 micron to 15 microns, such as from 1 micron to 5 microns, as determined by scanning electron microscopy (SEM).

4. The method of claim 1, wherein the particles comprise a population of nanoparticles.

5. The method of claim 4, wherein the population of nanoparticles has an average particle size of from 25 nm to less than 1 micron, such as from 25 nm to 200 nm or from 100 nm to 750 nm, as determined by scanning electron microscopy (SEM).

6. The method of any of claims 1-5, wherein the particles comprise a monodisperse population of particles.

7. The method of any of claims 1-6, wherein the two or more active components comprise from 51 mol % to 99 mol % of the amorphous glass, such as from 80 mol % to 95 mol % of the amorphous glass.

8. The method of any of claims 1-7, wherein the two or more amorphous forming components comprise from 1 mol % to 49 mol % of the amorphous glass, such as from 5 mol % to 25 mol % of the amorphous glass or from 5 mol % to 20 mol % of the amorphous glass.

9. The method of any of claims 1-8, wherein the two or more active components and two or more amorphous forming components are present in the amorphous glass at a molar ratio of from 1.1 : 1 to 50: 1, such as from 1.1 : 1 to 25: 1, from 2: 1 to 25: 1, from 2: 1 to 20: 1, from 4: 1 to 20: 1, from 5: 1 to 15: 1, or from 5: 1 to 10: 1.

10. The method of any of claims 1-9, wherein the two or more active components comprise silicon, tin, lead, antimony, germanium, gallium, indium, bismuth, or any combination thereof.

11. The method of any of claims 1-10, wherein the two or more active components can comprise silicon.

12. The method of any of claims 1-11, wherein the two or more active components can comprise tin.

13. The method of any of claims 1-12, wherein the amorphous glass comprises a SiSn-based glass.

14. The method of claim 13, wherein the two or more active components comprise silicon and tin, and wherein the silicon and the tin are present a molar ratio of from 1.1 : 1 to 20: 1, such as from 2: 1 to 15: 1 or from 3: 1 to 12: 1.

15. The method of any of claims 1-14, wherein the two or more amorphous forming components comprise iron, aluminum, titanium, copper, nickel, cobalt, manganese, zirconium, yttrium, boron, niobium, molybdenum, tungsten, or any combination thereof.

16. The method of any of claims 1-15, wherein the two or more amorphous forming components comprise one or more lanthanides.

17. The method of claim 16, wherein the one or more lanthanides comprise from 1 mol % to 25 mol % of the amorphous glass, such as from 5 mol % to 20 mol % of the amorphous glass or from 10 mol % to 20 mol % of the amorphous glass.

18. The method of any of claims 1-17, wherein the two or more amorphous forming components comprise one or more Group 4 elements.

19. The method of claim 18, wherein the one or more Group 4 elements comprise from 1 mol % to 15 mol % of the amorphous glass, such as from 1 mol % to 10 mol % of the amorphous glass or from 2 mol % to 8 mol % of the amorphous glass.

20. The method of any of claims 1-19, wherein the two or more amorphous forming components comprise one or more Group 13 elements.

21. The method of claim 20, wherein the one or more Group 13 elements comprise from 1 mol % to 8 mol % of the amorphous glass, such as from 2 mol % to 6 mol % of the amorphous glass or from 3 mol % to 4 mol % of the amorphous glass.

22. The method of any of claims 1-21, wherein the amorphous glass comprises a glass defined by the formula below:SixSny1AFMa2AFMb3AFMc4AFMd wherein1AFM,2AFM,3AFM, and4AFM represent different elements, each chosen from iron, aluminum, titanium, copper, nickel, cobalt, manganese, gallium, indium, zirconium, and yttrium; x is from 50 to 90; y is from 1 to 40; a is from 0.5 to 20; b is from 0.5 to 15; c is from 0 to 10; and d is from 0 to 10.

23. The method of any of claims 1-22, wherein the amorphous glass comprises a SiSnCeFeAlTi glass, such as SieoSnnCeisFesAhTi?.

24. The method of any of claims 1-22, wherein the amorphous glass comprises a SiSnFeAlTi glass, such as SivsSmsFeeAhTi?.

25. The method of any of claims 1-22, wherein the amorphous glass comprises a SiSnAlTi glass, such as SivsSmeAUTi?.

26. The method of any of claims 1-25, wherein the particles have an aspect ratio of 10 or less, such as an aspect ratio of 5 or less or an aspect ratio of 2 or less.

27. The method of any of claims 1-26, wherein the two or more amorphous forming components comprise inactive components.

28. The method of any of claims 1-27, wherein the particles further comprise a carbonaceous material disposed on a surface of the particles.

29. The method of any of claims 1-28, wherein the particles are dispersed in a binder.

30. The method of claim 29, wherein the binder comprises a polymeric binder such as vinylidene fluoride (PVDF), polyaniline, or a combination thereof.

31. The method of any of claims 29-30, wherein the binder comprises a conductive polymer.

32. The method of any of claims 29-31, wherein the binder comprises a carbonaceous material such as carbon black.

33. The method of any of claims 1-32, wherein the particles can react with and store working ions selected from the group consisting of lithium ions, sodium ions, potassium ions, or a combination thereof under conditions typically encountered during charging and discharging of a battery comprising the working ions.

34. An anode made by the methods of any one of claims 1-33.

35. An electrochemical cell comprising the anode made by the method of any of claims 1-33, a cathode, and an electrolyte disposed between the anode and the cathode.

36. The electrochemical cell of claim 35, wherein the electrochemical cell comprises a lithium ion battery, and wherein the cathode comprises a lithium-based cathode.

37. The electrochemical cell of claim 36, wherein the cathode comprises lithium iron phosphate, LiNii-xMnx / 2Cox / 2O2, wherein x = 0.4 or 0.2, or LiNi0.8Co0.15Al0.05O2.

38. The electrochemical cell of any of claims 36-37, wherein the electrochemical cell exhibits an energy density of at least 180 Wh / kg at room temperature, such as an energy density of from 180 Wh / kg to 3,500 Wh / kg at room temperature.

39. The electrochemical cell of any of claims 35-38, wherein the electrochemical cell exhibits a charge rate of from 1 minute to 10 minutes to 30% of a state of charge (SOC), a charge rate of from 1 minute to 10 minutes to 50% of a state of charge (SOC), a charge rate of from 1 minute to 10 minutes to 70% of a state of charge (SOC), and / or a charge rate of from 1 minute to 10 minutes to 90% of a state of charge (SOC).

40. A method of making a population of particles formed from an amorphous glass, the method comprising spray pyrolysis, optionally wherein the spray pyrolysis comprises: aerosolizing an aqueous solution comprising the amorphous glass in a solvent to form amorphous glass droplets; evaporating the solvent in the amorphous glass droplets to form dried amorphous glass droplets; and calcining the dried amorphous glass droplets to form the population of particles; wherein the amorphous glass comprises a glass defined by the formula below: SixSny1AFMa2AFMb3AFMc4AFMd wherein1AFM,2AFM,3AFM, and4AFM represent different elements, each chosen from iron, aluminum, titanium, copper, nickel, cobalt, manganese, gallium, indium, zirconium, and yttrium; x is from 50 to 90; y is from 1 to 40; a is from 0.5 to 20; b is from 0.5 to 15; c is from 0 to 10; and d is from 0 to 10.

41. The method of claim 40, wherein the population of particles comprises a population of microparticles.

42. The method of claim 41, wherein the population of microparticles has an average particle size of from 1 micron to 15 microns, such as from 1 micron to 5 microns, as determined by scanning electron microscopy (SEM).

43. The method of claim 40, wherein the population of particles comprises a population of nanoparticles.

44. The method of claim 43, wherein the population of nanoparticles has an average particle size of from 25 nm to less than 1 micron, such as from 25 nm to 200 nm or from 100 nm to 750 nm, as determined by scanning electron microscopy (SEM).

45. The method of any of claims 40-44, wherein the population of particles is monodisperse in size.

46. The method of any of claims 40-45, wherein the particles have an aspect ratio of 10 or less, such as an aspect ratio of 5 or less or an aspect ratio of 2 or less.