Anode for sodium-ion and potassium-ion batteries
09742027 · 2017-08-22
Assignee
Inventors
- Sean Vail (Vancouver, WA, US)
- Yuhao Lu (Vancouver, WA, US)
- Long Wang (Vancouver, WA, US)
- Motoaki Nishijima (Kanmaki-tyo, JP)
- Jong-Jan Lee (Camas, WA, US)
Cpc classification
H01M4/133
ELECTRICITY
H01M4/1393
ELECTRICITY
H01M4/0471
ELECTRICITY
H01M4/131
ELECTRICITY
Y02E60/10
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
H01M4/1391
ELECTRICITY
H01M2004/021
ELECTRICITY
H01M4/58
ELECTRICITY
H01M10/054
ELECTRICITY
International classification
H01M4/58
ELECTRICITY
H01M4/36
ELECTRICITY
H01M4/1391
ELECTRICITY
H01M4/133
ELECTRICITY
H01M4/131
ELECTRICITY
H01M4/62
ELECTRICITY
H01M4/1393
ELECTRICITY
Abstract
A first method for fabricating an anode for use in sodium-ion and potassium-ion batteries includes mixing a conductive carbon material having a low surface area, a hard carbon material, and a binder material. A carbon-composite material is thus formed and coated on a conductive substrate. A second method for fabricating an anode for use in sodium-ion and potassium-ion batteries mixes a metal-containing material, a hard carbon material, and binder material. A carbon-composite material is thus formed and coated on a conductive substrate. A third method for fabricating an anode for use in sodium-ion and potassium-ion batteries provides a hard carbon material having a pyrolyzed polymer coating that is mixed with a binder material to form a carbon-composite material, which is coated on a conductive substrate. Descriptions of the anodes and batteries formed by the above-described methods are also provided.
Claims
1. A sodium-ion or potassium-ion battery, the battery comprising: a transition metal hexacyanometallate (TMHCM) cathode; a non-aqueous electrolyte; an anode comprising: a conductive substrate; a carbon-composite material overlying the conductive substrate comprising: a hard carbon material; a conductive carbon material having a low surface area; a binder material; wherein a carbon-composite material is defined herein as a mixture of two or more different materials, in which at least one material is a carbon material; and, an ion-permeable membrane separating the anode from the cathode.
2. A sodium-ion or potassium-ion battery, the battery comprising: a transition metal hexacyanometallate (TMHCM) cathode; a non-aqueous electrolyte; an anode comprising: a conductive substrate; a carbon-composite material overlying the conductive substrate comprising: a hard carbon material; a metal-containing material; a binder material; wherein a carbon-composite material is defined herein as a mixture of two or more different materials, in which at least one material is a carbon material; and, an ion-permeable membrane separating the anode from the cathode.
3. A sodium-ion or potassium-ion battery, the battery comprising: a transition metal hexacyanometallate (TMHCM) cathode; a non-aqueous electrolyte; an anode comprising: a conductive substrate; a carbon-composite material overlying the conductive substrate comprising a hard carbon material with a pyrolyzed polymer coating; a binder material; wherein a carbon-composite material is defined herein as a mixture of two or more different materials, in which at least one material is a carbon material; and, an ion-permeable membrane separating the anode from the cathode.
4. A sodium-ion or potassium-ion battery, the battery comprising: a transition metal hexacyanometallate (TMHCM) cathode; a non-aqueous electrolyte; an anode comprising: a conductive substrate; a carbon-composite material overlying the conductive substrate comprising: a hard carbon material; a metal-containing material, excluding materials capable of forming an alloy with sodium and potassium, wherein an alloy is defined as a substance composed of two or more metals, or of a metal or metals with a nonmetal; a binder material; wherein a carbon-composite material is defined herein as a mixture of two or more different materials, in which at least one material is a carbon material; and, an ion-permeable membrane separating the anode from the cathode.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(15) In general, within an organic electrolyte, reversible capacity is consumed during the first cycle to form a solid electrolyte interface (SEI) layer on an anode, which suppresses further electrolyte decomposition. The corresponding irreversible capacity is clearly correlated with the surface of area(s) of the entire electrode since the SEI layer completely covers the interface between anode and electrolyte. Ketjenblack, for example, has a surface area of ˜1000 square meters per gram (m.sup.2/g) that gives rise to a large capacity loss (low coulombic efficiency) at the first cycle. As to a hard carbon electrode, carbon black is often used as an electronically conductive additive to reduce the electrode resistance and polarization. However, it is inevitable that a lower coulombic efficiency at the first cycle arises for a hard carbon electrode, which can be reduced from greater than 90% to 60% or lower. As a result, an HC anode was constructed with an electronically conductive network for use in sodium-ion or potassium-ion batteries, while maintaining a considerable coulombic efficiency.
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(17) [Method 1] Low Surface Area Carbonaceous Materials as Electronically Conductive Additives:
(18) The aforementioned observations indicate that high surface areas for conductive carbon materials lead to a high irreversible capacity and a low coulombic efficiency for a HC anode at the first cycle. In order to circumvent this problem, conductive carbon materials with low surface areas can be employed as electrode additives to prepare the HC electrode. The surface area of the conductive carbon materials can be 0<10 m.sup.2/g, 0<20 m.sup.2/g, 0<30 m.sup.2/g, 0<40 m.sup.2/g, 0<50 m.sup.2/g, 0<60 m.sup.2/g, 0<70 m.sup.2/g, 0<80 m.sup.2/g, 0<90 m.sup.2/g, or 0<100 m.sup.2/g. The HC anode materials may be mixed with conductive carbon materials and binders to make the electrode. Examples of binder candidates may be polytetrafluoroethylene (PTFE), polyvinylidene fluoride/difluoride (PVdF), carboxymethyl cellulose (CMC), sodium carboxymethyl cellulose (Na-CMC), styrene-butadiene rubber (SBR), alginic acid, sodium alginate, and combinations thereof, although other binder materials may be used.
(19) Operative examples of high-performance HC electrodes containing low-surface area conductive carbon materials as electrode additives are discussed in this section. Although HC is a carbonaceous anode material used for illustrative purposes, suitable alternatives such as soft carbons and graphite are similarly possible. HC electrodes were prepared using a slurry comprising HC, a low-surface area conductive carbon (surface area ˜45 m.sup.2/g), and PVdF (KYNAR HSV900) to afford a composition consisting of HC (75 wt %), low-surface area conductive carbon material (20 wt %), and PVdF (5 wt %). The resulting slurry was coated onto Cu foil.
(20) Coin cells (HC/Na half-cells) were fabricated from the aforementioned electrodes with a sodium Na) metal counter electrode, and a Na.sup.+-permeable membrane interposed between HC and Na electrodes, with 1M sodium hexafluorophosphate (NaPF.sub.6) in ethylene carbonate-diethyl carbonate (EC-DEC) as the electrolyte. Cycling was performed by maintaining the rates for both discharge and charge at 50 milliamperes per gram (mA/g) (0.2 C, 5 cycles).fwdarw.100 (mA/g) (0.4 C, 5 cycles).fwdarw.125 mA/g (0.5 C, 10 cycles).fwdarw.250 mA/g (1 C, 10 cycles).fwdarw.500 mA/g (2 C, 10 cycles).fwdarw.1000 mA/g (4 C, 10 cycles).fwdarw.50 mA/g (0.2 C) thereafter between 2 V and 5 mV. The discharge/charge curves for HC electrodes [HC (75 wt %), low-surface area conductive carbon material (20 wt %), PVdF (5 wt %)/Cu] with 3 different HC mass loadings (1.1 mg/cm.sup.2, 2.1 mg/cm.sup.2, and 3.3 mg/cm.sup.2) in the HC/Na half-cell configuration with 1M NaPF.sub.6 (EC-DEC) electrolyte are presented in
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(25) As can be seen from
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(27) Step 602 mixes a conductive carbon material having a low surface area, a hard carbon material, and a binder material. Step 604 forms a carbon-composite material, defined herein as a mixture of two or more different materials, in which at least one material is a carbon material. Step 606 coats the carbon-composite material on a conductive substrate. As mentioned above, the binder material may be a polymer or a mixture of polymers. The conductive carbon material typically has a surface area of less than 100 m.sup.2/g.
(28) [Method 2] Metal-Containing Materials as Electronically Conductive Additives:
(29) The above-described conductive carbon materials can be substituted by metal-containing materials. The surface area of the metal-containing materials can be 0<10 m.sup.2/g, 0<20 m.sup.2/g, 0<30 m.sup.2/g, 0<40 m.sup.2/g, 0<50 m.sup.2/g, 0<60 m.sup.2/g, 0<70 m.sup.2/g, 0<80 m.sup.2/g, 0<90 m.sup.2/g, 0<100 m.sup.2/g, 0<200 m.sup.2/g, 0<500 m.sup.2/g, or 0<1000 m.sup.2/g. The HC material may be mixed with metal-containing materials and binders to make the electrode. A nonexhaustive list of potential binders was included in the previous section.
(30) In addition, the metal-containing materials can be coated on, or be a component of a composite with HC materials. A HC material may be dispersed in an aqueous solution containing a dissolved metal salt or metal complex during which metal ions are absorbed on the surface of the hard carbon material. Upon addition of a chemical agent, such as a base to increase the solution pH, the metal ions absorbed on HC are converted to the corresponding metal hydroxides and/or metal oxides, forming a composite of metal-containing material and HC. In a specific scenario, a composite of Cu and HC can be used as an example. Accordingly, into an aqueous solution of copper(II) ions (Cu.sup.2+) is dispersed a HC material. During and following mixing, Cu.sup.2+ are absorbed onto the hard carbon surface. An appropriate solution of sodium hydroxide (NaOH) or similar is used to adjust the solution pH to form a composite of HC and copper hydroxides/copper oxides. The composite is used to fabricate an electrode with an appropriate binder. Following battery assembly and cycling with an appropriate counter electrode, the copper-containing materials in the hard carbon composite electrode are electrochemically reduced to metallic Cu, which consequently, forms a beneficial electronically conducting network within the HC electrode.
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(32) In one aspect, the metal-containing material 704 has a surface area of less than 100 m.sup.2/g. In another aspect, the metal-containing material 704 includes a transition metal. The metal-containing material 704 may take the form of elemental metals, metal hydroxides, metal oxides, or combinations thereof. Further, in some aspects the metal-containing material explicitly excludes materials capable of forming an alloy with sodium and potassium, where an alloy is defined as a substance composed of two or more metals, or of a metal or metals with a nonmetal.
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(34) [Method 3] Polymer Composite with Pyrolysis Approach:
(35) In this method HC materials are dispersed in a polymer to form a carbon-composite. Subsequently, the carbon-composite is thermally treated in a furnace at a temperature range of 300-2000° C., preferably under an inert atmosphere (pyrolysis), to afford a pyrolyzed polymer coating on the HC material that is subsequently mixed with appropriate binder to fabricate an electrode. Appropriate polymer materials for forming the pyrolyzed polymer coating include polymers that may have covalent carbon-carbon bonds and may include natural and synthetic polymers.
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(39) Providing the hard carbon material with the pyrolyzed polymer coating in Step 1102 may include the following substeps. Step 1102a provides a polymer material. Step 1102b disperses a hard carbon material within the polymer material. Step 1102c performs a thermal treatment, for example, by heating to a temperature in the range of 300 to 2000 degrees C. In one aspect, the heating is performed in an inert atmosphere. Step 1102d pyrolyzes the polymer.
(40) In summary, hard carbon is common to all three scenarios and is a feature of all three strategies for forming anode electrodes with low surface area and high coulombic efficiency. Furthermore, the anode electrode with HC material benefits from increased conductivity due to an electronically conductive network established by employing (1) conductive carbon materials with a low surface area, (2) metal-containing materials, or (3) pyrolyzed polymer coating on HC. Method 1 (HC plus conductive carbon) and Method 3 (pyrolyzed polymer coating) both involve conductive carbon materials (either physically added or formed as pyrolyzed polymer coating). For the metal-containing approach of Method 2, there are two variations. In the first case, elemental metal particles are mixed with HC. In the more elaborate variation, metal precursors are deposited (e.g., oxides) onto the surface of HC. During the battery first cycle (charge/discharge), the metal oxide is electrochemically (and irreversibly) reduced to elemental metal materials (on HC surface). Subsequently, the formed metal particles (which form a conductive network within the HC electrode), improve the conductivity of the electrode due to the high intrinsic conductivity of metals.
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(42) The electrolyte 1204 may be non-aqueous, a polymer, gel, or solid material. In the case of non-aqueous (liquid) electrolytes, the electrolyte may consist of a sodium and/or potassium salt dissolved in an organic solvent or mixture of organic solvents. A nonexhaustive list of possible sodium and potassium salts include sodium or potassium hexafluorophosphate (NaPF.sub.6 or KPF.sub.6), sodium or potassium perchlorate (NaClO.sub.4 or KClO.sub.4), sodium or potassium tetrafluoroborate (NaBF.sub.4 or KBF.sub.4), and sodium or potassium bis(trifluoromethanesulfonyl)imide (NaTFSI or KTFSI). Some examples of organic solvents include ethylene carbonate (EC), diethyl carbonate (DEC), dimethylcarbonate (DMC), propylene carbonate (PC), and organic ethers.
(43) The battery also comprises an anode 100. As described in detail in the explanation of
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(46) Methods for the fabrication of sodium-ion and potassium-ion battery anodes have been provided. Examples of particular materials and process details have been presented to illustrate the invention. However, the invention is not limited to merely these examples. Other variations and embodiments of the invention will occur to those skilled in the art.