AQUEOUS ELECTROCHEMICAL ENERGY STORAGE DEVICES AND COMPONENTS

• US 20150318530A1
• Filed: 04/29/2015
• Published: 11/05/2015
• Est. Priority Date: 05/01/2014
• Status: Abandoned Application

• Current Assignee: Sila Nanotechnologies Inc.
• Original Assignee: Sila Nanotechnologies Inc.
• Inventors: YUSHIN, Gleb, ZDYRKO, Bogdan, BERDICHEVSKY, Eugene Michael
• Application Number:
  US14/699,573
• Publication Number:
  US 20150318530A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01G 11/04 Hybrid capacitors
• CPC Class Codes: H01M 10/24 Alkaline accumulators
• CPC Class Codes: H01M 10/28 Construction or manufacture
• CPC Class Codes: H01M 10/36 Accumulators not provided for in groups H01M10/05-H01M10/34
• CPC Class Codes: H01M 10/4235 Safety or regulating additives or arrangements in electrodes, separators or electrolyte H01M10/4242 takes precedence
• CPC Class Codes: H01M 12/00 Hybrid cells; Manufacture thereof hybrid capacitors H01G11/00
• CPC Class Codes: H01M 2300/0005 Acid electrolytes
• CPC Class Codes: H01M 2300/0014 Alkaline electrolytes
• CPC Class Codes: H01M 4/0447 of complete cells or cells stacks
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/62 Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
• CPC Class Codes: H01M 4/628 Inhibitors, e.g. gassing inhibitors, corrosion inhibitors
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

Battery electrode compositions are provided for use in aqueous electrolytes and may comprise, for example, a current collector, active particles, and a conformal, metal-ion permeable coating. The active particles may be electrically connected to the current collector, and provided to store and release metal ions of an active material during battery operation. The conformal, metal-ion permeable coating may at least partially encase the surface of the connected active particles, whereby the conformal, metal-ion permeable coating impedes (i) direct electrical contact of an aqueous electrolyte with the active particles and (ii) aqueous electrolyte decomposition during battery operation. Such electrode compositions and corresponding aqueous batteries may facilitate the incorporation of advanced material synthesis and electrode fabrication technologies, and enable fabrication of high voltage and high capacity aqueous batteries at a cost lower than that of conventional metal-ion battery technology.

Claims

1. A battery electrode composition for use in aqueous electrolytes, comprising:

a current collector;

active particles electrically connected to the current collector, wherein the active particles are provided to store and release metal ions of an active material during battery operation; and

a conformal, metal-ion permeable coating that at least partially encases the surface of the connected active particles, whereby the conformal, metal-ion permeable coating impedes (i) direct electrical contact of an aqueous electrolyte with the active particles and (ii) aqueous electrolyte decomposition during battery operation.

2. The battery electrode composition of claim 1, wherein the aqueous electrolyte is a pH-neutral aqueous solution of a Li-based salt.

3. The battery electrode composition of claim 1, wherein the aqueous electrolyte is a pH-neutral aqueous solution of a Na-based salt.

4. The battery electrode composition of claim 1, wherein the aqueous electrolyte is a pH-basic aqueous solution with having a pH greater than 9.

5. The battery electrode composition of claim 1, wherein the aqueous electrolyte comprises a total salt concentration of at least of 3 molar.

6. The battery electrode composition of claim 1, wherein the active particles comprise composite particles having an inner core and an outer shell.

7. The battery electrode composition of claim 6, wherein the core, the shell, or both the core and the shell of the active particles is a nanocomposite.

8. The battery electrode composition of claim 6, wherein the core, the shell, or both the core and the shell of the active particles is formed with a radially changing composition, porosity, or average pore size from the center to the perimeter of each composite particle.

9. The battery electrode composition of claim 6, wherein the shell comprises Sn, Ti, Ta, Tl, Pb, Cd, Zn, Sb, or Bi.

10. The battery electrode composition of claim 1, wherein the conformal, metal-ion permeable coating comprises an inner layer and an outer layer.

11. The battery electrode composition of claim 10, wherein the inner layer comprises a material selected and arranged to:

electrically interconnect the active particles;

promote uniformity of the outer layer;

enhance mechanical stability of the coating;

protect the active material against dissolution or other reactions with the aqueous electrolyte;

or

impede decomposition of the aqueous electrolyte.

12. The battery electrode composition of claim 1, further comprising an aqueous electrolyte additive configured to decompose into the coating in response to application of an electrical potential below the decomposition potential of water.

13. The battery electrode composition of claim 1, wherein the aqueous electrolyte comprises:

a salt of a superacid;

a mixture of a salt of a superacid and a salt of another acid;

a mixture of a salt of an organic acid and a salt of an inorganic acids;

or

a mixture of a salt with a surfactant.

14. The battery electrode composition of claim 1, further comprising a pH-regulating functional group.

15. The battery electrode composition of claim 14, wherein the pH-regulating functional group is a polymeric pH-regulating functional group.

16. A battery, comprising:

anode and cathode electrodes, wherein at least one of the anode or the cathode electrodes comprises the battery electrode composition of claim 1; and

an aqueous electrolyte ionically coupling the anode and the cathode.

17. A method of fabricating an aqueous metal-ion battery electrode composition, comprising:

providing active particles to store and release metal ions of an active material during battery operation;

electrically connecting the active particles with a current collector; and

forming a conformal, metal-ion permeable so as to at least partially encase the surface of the connected active particles.

18. The method of claim 17, wherein the forming comprises:

providing an aqueous electrolyte additive; and

applying an electrical potential to induce decomposition of the aqueous electrolyte additive into the coating at the potential, wherein the current corresponding to the electrochemical process of water decomposition is below 10% of the total current involved in the additive decomposition.

19. The method of claim 17, further comprising filling the electrode with an electrolyte polymer bearing one or more pH-regulating functional groups for impeding water decomposition during battery operation.

20. The method of claim 17, wherein the current collector comprises 1% to 99.999% of Sn, Ti, Ta, Tl, Pb, Cu, Cd, Zn, Sb, or Bi.

21. The method of claim 17, wherein the current collector comprises:

metal wires or nanowires;

metal flakes;

a conformal metal coating;

or

a porous metal foil.