US Patent 9577251 Active electrode materials and methods for making the same

In an example of a method for making a silicon-based active electrode material, a silicon active material precursor is introduced into a carrier gas. Another active material precursor is introduced into the carrier gas prior to, simultaneously with or subsequent to the silicon active material precursor. The other active material precursor is selected from a tin active material precursor, an aluminum active material precursor, a graphene active material precursor, and combinations thereof. The carrier gas containing the precursors is exposed to plasma vaporization, and a material is formed. The material includes i) an alloy of phase separated silicon and tin and/or aluminum, or ii) a graphene layer having silicon nanoparticles and tin nanoparticles, aluminum nanoparticles, or combinations of tin and aluminum nanoparticles deposited on a surface thereof, or iii) a graphene layer having an alloy of phase separated silicon and tin, aluminum, or tin and aluminum deposited on a surface thereof.