DOPED SODIUM ANODE, BATTERY HAVING A DOPED SODIUM ANODE, AND METHODS OF USE THEREOF
20230335724 · 2023-10-19
Inventors
Cpc classification
International classification
Abstract
An anode of a battery comprises sodium metal, and a dopant, in the sodium metal. The anode has a thickness of at most 80 .Math.m, and the dopant is a metal with an electronegativity greater than sodium. A battery includes an anode, an anode charge collecting element in contact with the anode, a cathode, a cathode charge collecting element in contact with the cathode, an electrolyte in contact with the anode and the cathode, and a housing, enclosing the anode, anode charge colleting element, cathode, cathode charge collecting element and electrolyte. The anode in the battery comprises sodium metal doped with a dopant, and the dopant is present in an amount of 0.01 to 1.0 atomic percent.
Claims
1. An anode, comprising: sodium metal, and a dopant, in the sodium metal, wherein the anode has a thickness of at most 450 .Math.m, and the dopant is a metal with an electronegativity greater than sodium.
2. A method of making the anode of claim 1, comprising: melting sodium metal, introducing a dopant metal into the sodium metal to form molten doped sodium metal, solidifying the doped sodium metal, and forming the doped sodium metal into a foil having a thickness of at most 450 .Math.m.
3. A battery comprising: an anode, an anode charge collecting element in contact with the anode, a cathode, a cathode charge collecting element in contact with the cathode, an electrolyte in contact with the anode and the cathode, and a housing, enclosing the anode, anode charge colleting element, cathode, cathode charge collecting element and electrolyte, wherein the anode comprises sodium metal doped with a dopant, and the dopant is present in an amount of 0.01 to 1.0 atomic percent.
4. A method of generating electrical power with the battery of claim 3, comprising: connecting the anode and cathode of the battery to an external load to complete a circuit.
5. The anode of claim 1, wherein the dopant is present in an amount of 0.01 to 2.0 atomic percent.
6. The anode of claim 1, wherein the dopant is present in an amount of at most 1.0 atomic percent.
7. The anode of claim 1, wherein the dopant is present in an amount of 0.1 to 0.3 atomic percent.
8. The anode of claim 1, wherein the anode has a thickness of at most 30 .Math.m.
9. The anode of claim 1, wherein the dopant comprises at least one metal selected from the group consisting of: antimony, indium, lead, bismuth, thallium, and tin.
10. The anode of claim 1, wherein the dopant comprises tin.
11. The anode of claim 1, wherein the anode passes the resistance stability test.
12. The anode of claim 1, wherein the anode has a body centered cubic crystal structure.
13. The battery of claim 3, further comprising a separator in the housing.
14. The battery of claim 3, wherein the electrolyte is liquid.
15. (canceled)
16. The battery of claim 3, wherein the electrolyte comprises a salt, selected from the group consisting of: NaPFs, NaBF.sub.4, NaClO.sub.4, and mixtures thereof, and a solvent, selected from the group consisting of carbonates, ethers and mixtures thereof.
17. (canceled)
18. The battery of claim 3, wherein the anode charge collecting element and the cathode charge collecting element comprise a material independently selected from the group consisting of: copper, aluminum, steel and combinations thereof.
19. The anode of claim 1, wherein the anode has a thickness of at most 15 .Math.m.
20. The battery of claim 3, wherein the salt comprises NaPF.sub.6, the solvent comprises ethylene carbonate and propylene carbonate, and the cathode comprises Mo.sub.6S.sub.8.
21. The battery of claim 3, wherein the battery retains at least 70% capacity after 800 cycles.
22. A method of making the battery of claim 3, wherein the battery is assembled in dry air.
23. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0036] Despite the great progress in protecting sodium metal, there has been little effort on modulating the inherent physicochemical properties of metallic Na, which fundamentally limits the performance improvements. It is therefore of great interest and practical significance to explore approaches specifically designed to manipulate the fundamental behavior of Na metal. The addition of dopants as trace impurities is a powerful approach for altering the electrical or optical properties of a substrate, and has been widely demonstrated in fields such as solid-state electronics and lasers. The present invention describes anodes of sodium metal doped with trace amounts of a dopant, such as antimony, indium, lead, bismuth, thallium, or tin. The doped metal exhibits enhanced chemical stability and much better electrochemical reactivity. The dopant atoms are atomically dispersed in the Na crystal (
[0037]
[0038] The dopant may be any metal that has an electronegativity greater than the electronegativity of sodium. The dopant may be beryllium, magnesium, aluminum, calcium, scandium, titanium, vanadium, chromium, manganese, iron, nickel, cobalt, copper, zinc, gallium, germanium, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, silver, cadmium, indium, tin, antimony, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold, mercury, lead, bismuth, actinium, protactinium, thorium, neptunium, uranium, americium, plutonium, and curium. Preferably the dopant is antimony, indium, lead, bismuth, thallium, or tin, most preferably tin.
[0039] The anode of the present invention includes sodium metal doped with a dopant. The dopant may be present in an amount of 0.01 - 2.0 atomic percent, including 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, and 1.9. Preferably the dopant is present in an amount of 0.05 - 0.5 atomic percent. Preferably, the dopant does not form intermetallic phases, and is present interstitially or replaces a sodium atom in the sodium crystal structure.
[0040] The doped sodium may be pressed into foils with a thickness of 1 to 450 .Math.m. Preferably the foil has a thickness of less than 80 .Math.m, including 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, and 75 .Math.m. Most preferably, the foil has a thickness of at most 30 .Math.m.
[0041] Preferably the doped anode is stable in dry air. The surface corrosion of doped and undoped electrodes in dry air may be measured by measuring the R.sub.ct (charge transfer resistance) of doped and undoped sodium anodes. The doped anode preferably passes the resistance stability test which requires the doped anode to have a resistance, measured after 7 days of exposure in dry air, that is ⅒ or less than the resistance of an undoped sodium anode, when the resistance of the anodes is measured using electrochemical impedance spectroscopy (EIS) analysis of symmetric coin cells assembled with the doped and undoped sodium anodes with 1.0 M NaPF.sub.6 in ethylene carbonate/propylene carbonate (EC/PC) as the electrolyte (1:1 volume).
[0042] Optionally, the anode may be incorporated into a battery, having a cathode, electrolytes and a housing. The battery may also include charge collecting elements on the anode and cathode to gather or distribute the electrons. The charge collecting elements may be connected to an external circuit that is optionally connected to a load or to a recharging source.
[0043]
[0044] In a sodium-ion battery, the sodium ions move from the anode to the cathode during discharge and in the opposite direction during recharge. The electrolyte carries positively charged sodium ions from the anode to the cathode and vice versa through the separator. The movement of the sodium ions creates free electrons in the anode which creates a charge at the anode current collecting element. The electrical current then flows from the current collector on the cathode, through a load (device being powered), to the current collecting element on the anode. When the battery is being recharged the electrons and ions flow in the opposite directions.
[0045] Preferably the battery maintains a capacity of at least 50% of the battery’s initial capacity after 200 to 1000 cycles. The battery may retain a capacity of 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% and 100% of the battery’s initial capacity after 200 cycles. Most preferably the battery maintains a capacity of at least 70% of the initial capacity for 100, 120, 140, 160, 180, 200, 220, 240, 260, 280, 300, 320, 340, 360, 380, 400, 420, 440, 460, 480, 500, 520, 540, 560, 580, 600, 620, 640, 660, 680, 700, 720, 740, 760, 780 or 800 cycles.
[0046] The cathode material may be an oxide, such as sodium cobalt oxide, sodium manganese oxide, sodium nickel manganese oxide (NaNi.sub.xMn.sub.1-xO.sub.2 (x is between 0 and 1)), sodium nickel manganese cobalt oxide, sodium iron managanese oxide, sodium iron phosphate, sodium manganese phosphate, sodium vanadium phosphate, Na.sub.⅔Fe.sub.½Mn.sub.½O.sub.2 oxide, mixed P3/P2/O3-type Na.sub.0.76Mn.sub.0.5Ni.sub.0.3Fe.sub.0.1Mg.sub.0.1O.sub.2 oxide, or O3-type NaNi.sub.¼Na.sub.⅙Mn.sub.2/12Ti.sub.4/12Sn.sub.1/12O.sub.2 oxide. The cathode may include Mo.sub.6S.sub.8, which is a very stable cathode material. Prussian Blue Analogues (PBAs) may also be desirable with sodium cathode. PBAs include rhombohedral Na.sub.xMn[Fe(CN).sub.6], Na.sub.xCo[Fe(CN).sub.6] and rhombohedral Prussian white Na.sub.xFe[Fe(CN).sub.6].Math.0.18(9)H.sub.2O (x is in the range of 0 to 10) (U.S. Pat. No. 9,099,718 and Brant et al., “Selective Control of Composition in Prussian White for Enhanced Material Properties”, Chemistry of Materials, Vo. 31, No. 18, pp. 7203-7211 (2019)). The cathodes of Komaba et al. “P2-type Na.sub.x[Fe.sub.½Mn.sub.½]O.sub.2 made from earth-abundant elements for rechargeable Na batteries” Nature Materials, Vol. 11, No. 6, pp. 512-517 (2012) may also be used.
[0047] Other cathode materials of interest are sulfur and oxygen. Sodium-sulfur and sodium-oxygen batteries have advantages over sodium-ion cells because of their higher energy density and reduced cost from the use of sulfur. Sulfur has low conductivity, so the sulfur cathodes may also be paired with a highly conductive material to improve the conductivity. A carbon coating may be used to provide the missing electroconductivity. Sulfur based electrodes include copolymerized sulfur, sulfur-graphene oxide, and sulfur/sodium-sulfide.
[0048] Separators are preferred components in liquid electrolyte batteries. In the case of a liquid electrolyte, the separator is a porous material that is soaked with the electrolyte and holds it in place. The separator needs to be an electronic insulator while having minimal electrolyte resistance, maximum mechanical stability, and chemical resistance to degradation in the highly electrochemically active environment. In addition, the separator often has a safety feature, called “thermal shutdown”, which at elevated temperatures, melts or closes its pores to shut down the sodium-ion transport without losing its mechanical stability. Separators are either synthesized in sheets and assembled with the electrodes or deposited onto one electrode in situ. A separator generally includes a polymeric membrane forming a microporous layer. The separator may be made from nonwoven fibers, such as cotton, nylon, polyesters, glass; polymer films, such as polyethylene, polypropylene, poly (tetrafluoroethylene), polyvinyl chloride; ceramic; and naturally occurring substances, such as rubber, asbestos, or wood. The separator materials described in Arora, P. et al., Battery Separators Chemical Reviews 2004 104 (10), pg. 4419-4462 may also be used.
[0049] The electrolyte provides a medium for the transport of the sodium ions from the cathode to the anode and vice versa. Types of electrolytes include liquid, polymer, and solid-state electrolytes. Liquid electrolytes in sodium-ion batteries include salts, such as NaFSI, NaTFSI, NaPF.sub.6, NaBF.sub.4, and NaClO.sub.4, and a solvent, such as ethylene carbonate, propylene carbonate dimethyl carbonate, diethyl carbonate, dimethoxyethane, diglyme, triethylene glycol dimethyl ether, and tetraethylene glycol dimethyl ether or mixtures thereof. The selection of the electrolyte may be influenced by the selection of the cathode material. One skilled in the art would select an appropriate electrolyte, an appropriate electrolyte volume, and an appropriate electrolyte concentration based on the cathode material, separator material, anode material, and cell design. The concentration of the electrolyte may be 0.1 M to 10.0 M, including 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 2.0, 3.0, 4.0, 5.0, 6.0, 7.0, 8.0, and 9.0 M. Preferably the concentration of the electrolyte is 0.5-2.0 M. Preferably the electrolyte is NaPF.sub.6 in ethylene carbonate/dimethyl carbonate (EC/DMC) or NaPF.sub.6 in ethylene carbonate/propylene carbonate (EC/PC). The ratio of the ethylene carbonate to propylene carbonate is preferably 1:1 by volume.
[0050] The electrolyte may be a solid or semi solid such as a ceramic. Solid electrolytes avoid the risk of leaks, and a separator is not necessary as the solid electrolyte prevents contact between the anode and the cathode. Solid ceramic electrolytes are mostly sodium metal oxides or sulfides. Common ceramic electrolytes are sodium super ion conductors (NASICON), β″-Al.sub.2O.sub.3 solid electrolyte (BASE), or sodium aluminum titanium phosphate (“NATP”). The solid electrolytes described in Wang, et al., “Development of solid-state electrolytes for sodium-ion battery-A short review”, Vol. 1, pp. 91-100 (2019) may also be used.
[0051] The current collecting element collects the electrons from the anode during discharge, prior to the electrons entering the external circuit. The current collecting element on the cathode will distribute the electrons to the cathode material. During recharging the electrons move in the opposite direction. The current collecting elements may comprise aluminum, copper, steel, or other conductive materials. The charge collecting elements include flexible carbon felts, porous carbon and silver nanowire meshes, which may provide a “host” for the sodium.
[0052] The housing encloses the battery and prevents the electrolyte for leaking. The housing may comprise metal or plastics. The housing may be rigid or flexible. Flexible housing materials allows for expansion of the cell during recharging, or for expansion caused by gas formation inside the battery. The battery structures and manufacturing techniques described in Schroder et al., “Comparatively assessing different shapes of litihium-ion battery cells”, ScienceDirect Procedia Manufacturing, Vol. 8, pg. 104 - 111 (2017) may also be used.
[0053] The battery shape and design may be selected from various shapes to optimize the battery and avoid overheating, increase energy density, or reduce self-discharge. Common battery designs include small cylindrical (solid body without terminals, such as those used in older laptop batteries), button cells, prismatic cells, large cylindrical (solid body with large threaded terminals), pouch (soft, flat body, such as those used in cell phones and newer laptops; also referred to as Na-ion polymer or sodium polymer batteries), and rigid plastic case with large threaded terminals (such as in electric vehicles).
EXAMPLES
Example 1
Materials Synthesis:
[0054] This example focuses on Sn as the dopant, but the same principle can be used to produce Sb, In, Pb, Bi, Tl, etc. doped Na electrodes as long as the dopant metal is soluble in molten Na. The atomic concentration of Sn can be varied from 0.01% to 1% to ensure complete solvation without formation of crystalline compounds, as determined from the Sn-Na phase diagrams (
Electrochemical Measurements:
[0055] All battery studies were performed using type 2025 coin cells assembled in an Ar-filled glovebox (
Results:
[0056]
[0057] The surface stability of Na electrodes with and without Sn-doping in dry air where the relative humidity was <5% was compared. The undoped Na electrodes exhibited typical aggressive chemical reactivity and generated greyish tarnishing layers almost immediately (
[0058] The stability of doped Na electrodes in batteries was first evaluated using symmetric coin cell configuration, which was assembled using two Na electrodes with identical composition. These batteries were cycled at either 0.5 mA cm.sup.-2 or 4.0 mA cm.sup.-2 at a capacity of 2.0 mAh cm.sup.-2 for each cycle. The Sn doped Na electrodes exhibited outstanding stability under both testing conditions (
[0059] In addition to symmetric cells, the improved stability of doped Na electrodes was also confirmed in Na metal full cells. These full cells were assembled with a prototype Mo.sub.6S.sub.8 cathode (with a real capacity of 1.5 mAh cm.sup.-2). Mo.sub.6S.sub.8 was chosen for this demonstration because it is a very stable material and any observed degradation can be assigned to failures on the anode side (undoped Na vs. doped Na). Na electrodes with different concentrations of Sn dopant were prepared and examined, and the results are compared in
[0060] The cycled batteries were then disassembled and the sodium anodes were analyzed using scanning electron microscope (
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