Patent Application
20170283524
The present disclosure relates to cathode materials and method for making the same, and particularly relates to sulfur based cathode composite materials of lithium ion batteries.
Polyacrylonitrile (PAN) is a high molecular weight polymer composed of saturated carbon skeleton containing cyano groups (CN) on alternate carbon atoms. PAN itself is not electrically conductive but can be sulfurized to form sulfurized polyacrylonitrile, which is electrically conductive and chemically active. Specifically, the PAN powder and elemental sulfur are mixed to form a mixture, which is then heated and completely reacted at 300° C., to form sulfurized polyacrylonitrile. The sulfurized polyacrylonitrile can be used as a cathode material of a lithium ion battery. The PAN may have a sulfurization and a cyclization reaction during the process of forming the sulfurized polyacrylonitrile. Thus, the sulfurized polyacrylonitrile is a conjugated polymer having long-range n-type bonds. The sulfurized polyacrylonitrile used as the cathode material of the lithium ion battery has a high specific capacity.
One aspect of the present disclosure is to provide a method for making a sulfur based cathode composite material by uniformly mixing the PAN with the sulfur.
A method for making a sulfur based cathode composite material comprises: co-dissolving PAN with elemental sulfur in a first solvent to form a first solution; adding an additive in the first solution to mix with the dissolved PAN and elemental sulfur, the additive is at least one of metal or metal sulfide; varying an environment of the PAN and the elemental sulfur to simultaneously precipitate the PAN and the elemental sulfur, and due to a solubility decrease in the changed environment, a precipitate with the additive is formed; and heating the precipitate to chemically react the PAN with the elemental sulfur to synthesize the sulfur based cathode composite material.
In the method for making the sulfur based cathode composite material, by dissolving the PAN and the elemental sulfur, uniform mixing in the liquid phase can be achieved. The solubility is reduced to simultaneously precipitate the two to form the uniform solid mixture, which is conducive to reaction between the PAN and the elemental sulfur in the subsequent heat treatment process.
Implementations are described by way of example only with reference to the attached figures.
Numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures, and components have not been described in detail so as not to obscure the related relevant feature being described.
Referring to
S1, dissolving polyacrylonitrile (PAN) and elemental sulfur together in a first solvent to form a first solution;
S2, adding an additive to the first solution to mix with the dissolved PAN and the dissolved elemental sulfur, the additive being at least one of metal and metal sulfide;
S3, changing an environment in which the PAN and the elemental sulfur are located in, the PAN and the elemental sulfur are simultaneously precipitated by changing the environment, and formed into a precipitate together with the additive; and
S4, heating the precipitate to chemically react the PAN with the elemental sulfur to form the sulfur based cathode composite material.
In S1, the PAN and the elemental sulfur are proportionally dissolved in the first solvent having a temperature in the first temperature range to form the first solution. The first temperature range (T1) is greater than or equal to 100° C. and less than or equal to 200° C. (100° C.≦T1≦200° C.). The elemental sulfur and the PAN, having a mass ratio of 1:1 to 10:1, can be completely dissolved in the first solvent. A total concentration of the PAN and the elemental sulfur in the first solution can be in a range from about 10 g/L to about 100 g/L. In one embodiment, the elemental sulfur and the PAN, having a mass ratio of 1:1 to 4:1, can be dissolved in the first solvent. A proper control of the total concentration of the first solution is advantageous for both the production of the precipitate and the uniform mixing of the PAN and the elemental sulfur.
The PAN can be a homopolymer of an acrylonitrile monomer or a copolymer of the acrylonitrile monomer and a second copolymerization unit. The second copolymerization unit can be selected from, but not limited to, at least one of methyl acrylate, methyl methacrylate, itaconic acid, dimethyl itaconate, and acrylamide. A molecular weight of the PAN is not limited, and is can be in a range from 30,000 to 150,000. The type of the first solvent is not limited as long as the PAN and the elemental sulfur are soluble to the first solvent in the first temperature range (the solubility can be greater than 1). The first solvent can be N-methylpyrrolidone, dimethylformamide, dimethylsulfoxide, dimethylacetamide or mixtures thereof. The first solvent is used to physically dissolve the elemental sulfur and the PAN, and does not chemically react with the elemental sulfur or the PAN.
In S2, the additive can be in shape of powder or particles, and the particle size can be less than or equal to 5 microns. The additive can be a metal M or a sulfide (MxSy) of the metal M. The type of the metal M can be determined according to a function of the additive, and the function can be, but is not limited to:
(1) a catalyst to promote the dehydrocyclization reaction of the PAN during the heating of S4;
(2) reacting to produce a metal sulfide during the heating of S4, and the metal sulfide has an electrochemical lithium storage capacity; and
(3) absorbing polysulfide ions in charge and discharge process of the sulfur based cathode composite material.
The additive can be at least one of a powder of a transition metal (e.g., iron, cobalt, nickel, molybdenum, or tungsten) and a sulfide of the transition metal powder.
An amount of the additive is less than or equal to 10% of the total mass of the PAN and the elemental sulfur, such as less than or equal to 1% of the total mass of the PAN and the elemental sulfur. The additive does not react chemically with the first solvent or the second solvent.
The solubility of the additive in the first solvent is not limited, and the additive can be soluble or insoluble to the first solvent. When the additive is insoluble in the first solvent, the additive powder or particles can be uniformly dispersed in the first solvent by mechanical stirring or ultrasonic oscillation.
In one embodiment, the additive can be added directly to the first solution. In another embodiment, the additive can be separately dispersed in a small amount of the first solvent to form a dispersion, and then the dispersion is mixed with the first solution. The first solution after adding with the additive can be maintained at a temperature in the first temperature range, i.e., 100° C.≦T1≦200° C., regardless of whether or not the additive is added in the form of the dispersion, and the total concentration of the PAN and the elemental sulfur is still in the range of 10 g/L to 100 g/L.
In S3, the mixture of the PAN, the elemental sulfur, and the additive is transferred from a first environment to a second environment so that the solubilities of both the PAN and the elemental sulfur are reduced such that the PAN and the elemental sulfur are able to precipitate and become a solid precipitation from the dissolved state. An amorphous elemental sulfur or the elemental sulfur with a lower crystallinity can be obtained by reducing the solubility and precipitating the elemental sulfur, which is conducive to improve the electrochemical performance of the sulfur based cathode composite material. In addition, the simultaneous precipitation of the PAN and the elemental sulfur in the second environment is a physical precipitation process due to the decrease of the solubility. It is not the PAN and the elemental sulfur formed by chemical reaction in this process. In addition, when the additive is also dissolved in the first solvent, the environmental change also causes the additive to precipitate simultaneously with the PAN and the elemental sulfur. If the additive is insoluble in the first solvent, the additive can have no state change and remain as solid powder or particles from the first environment to the second environment. The precipitated solid PAN is homogeneously mixed with the elemental sulfur and the additive. The final precipitated substance obtained in S3 comprises uniformly mixed PAN, elemental sulfur, and additive. In one embodiment, the PAN is coated on the surface of the elemental sulfur. The particle size of the precipitate can be less than or equal to 10 microns.
The first environment can be a first solvent capable of dissolving the PAN and the elemental sulfur at a predetermined temperature and pressure. The temperature of the first environment can be in the first temperature range, and the pressure of the first environment can be atmospheric pressure. Since the solubility of the substance is related to the type of solvent and the temperature and pressure at which the substance is dissolved, the solubility of the PAN and the elemental sulfur can be reduced by at least one of: (1) changing the type of solvent; (2) changing the temperature; and (3) changing the pressure. That is, the second environment has at least one of the three above-described changed conditions compared to the first environment.
(1) Example for Changing the Solvent:
In one embodiment of S3, the first solution containing the additive is transferred to the second solvent, and the PAN and the elemental sulfur are simultaneously precipitated as a solid precipitate together with the additive. The solubility of the elemental sulfur in the second solvent is smaller than in the first solvent. The solubility of the PAN in the second solvent is smaller than in the first solvent. The additive can be insoluble in the second solvent or less soluble in the second solvent than in the first solvent. In one embodiment, the PAN, the elemental sulfur, and the additive are insoluble in the second solvent.
The transfer process can be accompanied with agitation or oscillation, so that the two solvents are fully and uniformly mixed. The temperature can be further varied while changing the solvent. In particular, the first solution having the first temperature in the first temperature range and containing the additive can be added to the second solvent having the second temperature in the second temperature range, and the second temperature is lower than the first temperature. The temperature difference between the first temperature and the second temperature can be greater than or equal to 50° C. The second temperature range (T2) can be smaller than or equal to 50° C. (T2≦50° C.) and greater than the freezing points of the second solvent and the first solvent. Since the first solution is added to the second solvent to have the first solvent mixed with the second solvent, in order to reduce the solubilities of the PAN and the elemental sulfur more significantly in the mixed solvent, a volume ratio of the first solvent to the second solvent can be 1:1 to 1:5. The type of the second solvent is not limited as long as the PAN, the elemental sulfur, and the additive are insoluble in the second solvent in the second temperature range. The second solvent can be water, ethanol, methanol, acetone, n-hexane, cyclohexane, diethyl ether, or mixtures thereof. The time used for completing the transfer of the first solution to the second solvent can be controlled within 10 seconds to have a rapid precipitation. Otherwise, the PAN and the elemental sulfur are sufficiently agitated or stirred during the transfer to cause the rapid precipitation. The rapid precipitation can result in a uniform coating of the PAN on the surface of the elemental sulfur to form a core-shell structure, which facilitates the reaction of PAN with the elemental sulfur during the subsequent heating, while also prevents the loss of the elemental sulfur during the heating, and can reduce the corrosion caused by the elemental sulfur to the equipment.
The simultaneously precipitation of the PAN and the elemental sulfur in the second solvent is a physical precipitation process in which the solubilities of the PAN and the elemental sulfur originally dissolved in the first solvent are reduced by being transferred to the second solvent, thereby precipitating the solid substance, rather than through a chemical reaction to synthesize the PAN and the elemental sulfur. In addition, when the additive is soluble in the first solvent, the additive can be precipitated with the PAN and the elemental sulfur in the second solvent; and when the additive is insoluble in the first solvent, the additive can have no state change and remain as solid powder or particles during the transfer from the first solvent to the second solvent.
After S3, the method can further comprise a step of filtering out the precipitate from the second solvent.
(2) Example for Changing the Temperature:
In another embodiment of S3, the first solution in the first temperature range containing the additive can be freeze-dried, and the PAN and the elemental sulfur are simultaneously precipitated to form a solid precipitate together with the additive. The freeze-drying conditions are not particularly limited.
(3) Example for Changing the Pressure:
In yet another embodiment of S3, the first solution in the first temperature range containing the additive is depressurized, to simultaneously precipitate the PAN and the elemental sulfur to form a solid precipitate together with the additive.
In S4, the precipitate is heated in vacuum or a protective atmosphere at a temperature equal to or above 250° C., such as in a range from 300° C. to 450° C., and the heating time can be decided based on the amount of the precipitate, such as from 1 hour to 10 hours. The protective atmosphere can be at least one of an inert gas and a nitrogen gas.
In the heating process, the elemental sulfur as a catalyst can catalyze the dehydrogenation of the PAN to form a main chain similar to the polyacetylene structure, and the side chain, the cyano group, is cyclized to form a cyclized polyacrylonitrile having a structural unit
wherein n is an integer greater than 1. Furthermore, the cyclized polyacrylonitrile simultaneously reacts with the molten-state elemental sulfur to embed the elemental sulfur in the cyclized polyacrylonitrile to obtain a sulfurized polyacrylonitrile. The sulfur particles of elemental sulfur or sulfur group (Sx) are covalently bonded to the C atom or the N atom in the structural unit
to form a structural unit such as
or
wherein n is an integer greater than 1, and x is not limited, such as an integer from 1 to 8. Other structural units may also be present in the molecule of the sulfurized polyacrylonitrile, depending on the heating conditions, such as the temperature.
The additive can be used as a catalyst to promote the dehydrocyclization reaction of the PAN. In addition, the additive can also react with the elemental sulfur to form the metal sulfide. The metal sulfide has the ability of electrochemical lithium storage, which is conducive to improve the discharge specific capacity of the sulfur based cathode composite material. Further, the additive can absorb polysulfide ions during the charging and discharging process of the sulfur based cathode composite material, thereby reducing the loss of the active material and improving the battery performance.
9 g of sublimed sulfur and 3 g of PAN are weighed, and dissolved in 200 mL of 120° C. oil-bathed N-methylpyrrolidone until the starting materials are completely dissolved to form the first solution. A molybdenum powder or its corresponding sulfide powder is added to the first solution and uniformly dispersed. A mass of the powder is 0.1% of the total mass of the sublimed sulfur and the PAN. The first solution containing the molybdenum powder or its corresponding sulfide powder is rapidly transferred to 200 mL of ice-bathed ethanol in 3 seconds to obtain the precipitate. The precipitate is dried in at 60° C. in vacuum. After drying, the precipitate is heated at 300° C. for 6 hours, and the product is the sulfurized polyacrylonitrile composite containing molybdenum.
Comparative Example 1 is similar to Example 1, without any additive. Specifically, 9 g of sublimed sulfur and 3 g of PAN are weighed, and dissolved in 200 mL of 120° C. oil-bathed N-methylpyrrolidone until the starting materials are completely dissolved to form the first solution. The first solution is rapidly transferred to 200 mL of ice-bathed ethanol in 3 seconds to obtain the precipitate. The precipitate is dried in at 60° C. in vacuum. After drying, the precipitate is heated at 300° C. for 6 hours, and the resulting product is the sulfurized polyacrylonitrile without molybdenum.
Lithium ion batteries are assembled respectively using the products of Example 1 and Comparative Example 1 as the cathode active materials. The electrochemical performances of the lithium ion batteries are tested. Specifically, 85% to 98% of the cathode active material, 1% to 10% of a conducting agent, and 1% to 5% of a binder by mass are mixed and coated on the surface of the aluminum foil as a cathode electrode. The lithium metal is used as an anode electrode. Lithium hexafluorophosphate (LiPF6) is dissolved in a mixed solvent of ethylene carbonate (EC) and methyl ethyl carbonate (EMC) in a volume ratio of 1:1 to form an electrolyte having 1 mol/L of the LiPF6. The two lithium ion batteries are galvanostatic charged and discharged using a current rate of 0.1 C.
Referring to
Finally, it is to be understood that the above-described embodiments are intended to illustrate rather than limit the present disclosure. Variations may be made to the embodiments without departing from the spirit of the present disclosure as claimed. Elements associated with any of the above embodiments are envisioned to be associated with any other embodiments. The above-described embodiments illustrate the scope of the present disclosure but do not restrict the scope of the present disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201410794871.5 | Dec 2014 | CN | national |
This application claims all benefits accruing under 35 U.S.C. §119 from China Patent Application No. 201410794871.5, filed on Dec. 19, 2014 in the State Intellectual Property Office of China, the content of which is hereby incorporated by reference. This application is a continuation under 35 U.S.C. §120 of international patent application PCT/CN2015/096321 filed on Dec. 3, 2015, the content of which is also hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/CN2015/096321 | Dec 2015 | US |
| Child | 15627255 | US |
