Patent Application
20230352685
The present invention relates to a novel method of preparing sulfur functionalized graphene, which produced graphene with high sulfur loading and low residual fluorine content. The resulting material allows forming electrodes for lithium-sulfur batteries with a high specific capacity and high cycling stability.
Lithium-ion batteries (LIBs) are a rechargeable energy storage system that has dominated the electronics market as a power source for portable and larger devices since early 1990s. However, with the rapid increase of portable devices and electric vehicles employed in personal, occupational and military applications, the demand for batteries with higher performance and lower cost also increases. Thus, considerable research efforts have been devoted to the development of advanced electrical energy storage devices that can offer high energy density. Lithium-sulfur batteries (LSBs) could offer a very promising energy storage system alternative because of their high theoretical specific capacity (1672 mAh g−1) and specific energy (2600 Wh kg−1). Moreover, sulfur is environmentally friendly, naturally abundant and a key byproduct of the petroleum industry rendering it attractive for its valorization and commercialization in high-tech areas such as the portable energy storage. However, several bottlenecks hinder the practical development of the LSBs, such as sulfur's poor conductivity and large volume changes upon charge/discharge, which restrict the efficient and long-life operation. More importantly, the “shuttle effect” of the soluble lithium polysulfides (Li2Sn, n≥4)—formed as byproducts during the charge/discharge process—lead to low coulombic efficiency, low sulfur utilization and fast capacity-fade.
Different strategies have emerged to tackle the above-mentioned problems, such as the fabrication of cathodes, using materials acting as hosts for sulfur—to make it more stable—, or functional separators, which hinder the shuttling of lithium polysulfides. The design of composite cathodes in order to achieve high sulfur loading, utilization and stability is the first key step for leveraging the hallmarks of LSBs. In this regard, nanostructured carbon-based materials are usually used, because they exhibit high porosity for hosting sulfur, good electrical conductivity, large surface areas and excellent mechanical properties. In a pioneering work (X. L. Ji et al. Nat. Mater. 2009, 8, 500-506), an ordered mesoporous carbon for sulfur encapsulation was exploited in order to improve the utilization of sulfur and restrain the “shuttle effect”. However, such conventional porous carbon hosts result into poor cycling stability because of the weak interaction between the polar polysulfides and the non-polar carbon, highlighting the need for different carbon chemistries and composites, such as designer carbons with tailor-made chemical groups on their surface. Such functional groups should anchor the polysulfides effectively, limiting the “shuttle effect” during charge/discharge process for stable cycling. In addition, replacing porous carbons for the physical entrapment of sulfur, appropriately functionalized graphene could be used as a building block for the controlled assembly of highly stable/highly sulfur-loaded cathodes, which would additionally offer better electrical conductivity, Another approach to block the “shuttle effect” is the replacement of elemental sulfur with short-chain polysulfides, covalently bound to the surface of a carbon, and preferably on graphene for higher conductivity—thus mitigating to some extent the insulating nature of sulfur.
In order to achieve this, we considered fluorinated graphite and its few-layered fluorographene analogue (from now on termed simply fluorographene), which is a starting material for the preparation of several covalently functionalized few-layered graphene derivatives (from now on termed simply graphene derivatives), due to the electrophilicity of the carbon atoms (actually of the carbon radical defects) and thus their high reactivity with many nucleophiles, even under mild conditions. A previous work (V. Urbanová et al. Adv. Mater. 2015, 27, 2305-2310) showed the first example of the covalent functionalization of fluorographene with thiol/sulfhydryl groups (—SH), by simple nucleophilic substitution of fluorine atoms in a polar solvent. Nevertheless, sulfur in the —SH groups is not proper for battery cathode materials since it is already in a reduced state. Another issue in that graphene-SH derivative, was that carbon atoms were bonded to only one S atom, leading to very small S content (5 at. %, as reported).
The present invention provides a method for preparation of sulfur-functionalized graphene which contains the following steps:
a) providing a dispersion of fluorinated graphite;
b) subjecting the dispersion of fluorinated graphite to sonication and/or mechanical treatment and/or thermal treatment;
c) preparing a metal polysulfide, starting from a metal sulfide and sulfur;
d) contacting the product from step b) with the product of step c) at a temperature within the range of 10-110° C.;
e) separating the solid product formed in step d) from the solution.
The term “fluorinated graphite” includes fluorographite, graphite fluoride, fluorinated graphite, and exfoliated forms of these materials. Fluorinated graphites are also available under the name poly(carbon monofluoride), carbon monofluoride or poly(carbon fluoride). The initial content of fluorine in the starting fluorinated graphite is typically at least 40 at. %, more preferably at least 45 or at least 50 at. %, relative to the total atoms present in the sample and determined by X-ray photoelectron spectroscopy (XPS) using an Al—Kα source.
The term “sulfur-functionalized graphene” means graphene with S atoms and polysulfide chains covalently bonded on the graphene surface. This term encompasses single-layer graphene, as well as materials comprising single-layer graphene in a mixture with moieties (e.g., flakes) or particles containing a plurality of graphene layers. This term also covers graphene wherein a small amount of fluorine is present as well (max. around 10 at. %).
The dispersion prepared in step a) is a dispersion of fluorinated graphite in a solvent. The solvent is preferably an aprotic polar solvent. The solvent may preferably be selected from dimethylformamide (DMF), dimethylsulfoxide (DMSO), N-methyl-2-pyrrolidone (NMP), glycols such as ethylene glycol, and fixtures thereof. Less polar or non-polar solvents such as acetonitrile, benzene, toluene or chlorobenzene may be used in combination with a polar organic solvent (for example DMF, NMP, dimethyl sulfoxide, dimethylacetamide).
The invention also encompasses embodiments in which a different solvent is used for sonication and/or mechanical treatment and/or thermal treatment than the solvent used for the reaction with the metal polysulfide reagent.
The step of sonication and/or mechanical treatment and/or thermal treatment yields a mixture containing fluorinated graphene and exfoliated fluorinated graphite particles.
Sonication is typically carried out at a frequency range of 20 kHz to 100 kHz and for a period of at least 2 hours, more preferably of at least 3 hours, even more preferably at least 4 hours.
The thermal treatment of the sonicated graphite fluoride with the metal polysulfide (step d) is typically carried out at the temperature range of 10-110° C. in an inert atmosphere and for a period of at least 1 hour or preferably at least 6 hours, more preferably at least 24 hours, even more preferably 72 hours.
The mechanical treatment preferably includes at least one treatment selected from high-shear mixing, stirring, vigorous stirring, stirring with magnetic bar, stirring with a mechanical stirrer. The mechanical treatment is most typically carried out by high-shear mixing or magnetic bar stirring.
The preferred treatment in step h) is sonication and/or mechanical treatment. Particularly preferred is mechanical treatment (in particular stirring) followed by sonication,
The metal in the polysulfide and sulfide in step c) is preferably an alkali metal or an alkaline earth metal. More preferably, the metal is selected from sodium, potassium and magnesium; most preferably, the metal is sodium.
The metal polysulfide is preferably added to the reaction mixture in step as a powder.
After contacting the product of step h) containing exfoliated fluorinated graphite/fluorinated graphene with the metal polysulfide reagent, the mixture is typically subjected to heating to a temperature within the range of 10-110° C., more preferably 20-100° C., even more preferably 50-90° C. The heating is preferably carried out for at least 4 hours, preferably for 4 hours to 20 days, even more preferably for at least 8 hours, yet more preferably for at least 24 hours, and even more preferably for at least 2 days (48 hours) or for at least 3 days (72 hours). The longer is the period of heating, the higher is the sulfur functionalization degree.
The weight ratio (mass ratio) of the starting fluorinated graphite to the metal polysulfide is preferably in the range of 1:2 to 1:20, more preferably 1:2 to 1:10, The optimum weight ratio is about 1:8 for sodium polysulfide.
The step of separation of the product (sulfur functionalized graphene) may be performed by known techniques such as centrifugation, sedimentation or filtration.
The solvent used in the process is preferably a polar solvent. The solvent may preferably be selected from dimethylformamide (DMF), dimethylsulfoxide (DMSO), N-methyl-2-pyrrolidone (NMP), N,N-dimethylacetamide (DMA), glycols such as ethylene glycol, and mixtures thereof.
The method of the invention allows to prepare graphene containing sulfur in the form of polysulfides and sulfur (S) atoms, sodium (as counter-ions of the terminal S atoms of the polysulfide chains) and fluorine atoms. The final sulfur-functionalized graphene usually contains residual fluorine atoms, but the method allows to reliably achieve a higher sulfur mass loading than most methods known in the prior art; the achieved sulfur loading is about 80 wt. % when the reaction of step d) is performed for 48 hours using a mass ratio of sodium polysulfide:fluorographene 8:1 in 80° C., at least 74 wt. % in 50° C. and at least 70 wt. % in room temperature. The process allowing to achieve these properties is simple and effective and uses economically effective starting compounds.
In particular, the method of the invention is the only wet-process chemical method which can achieve such high sulfur loading, covalently bonded to carbon atoms of graphene, which were previously bonded to fluorine atoms. Additionally, it is the only method achieving a high sulfur loading at relatively low reaction temperature.
The use of metal polysulfide instead of elemental sulfur offers the advantage of having the highly nucleophilic edges which react with the electrophilic carbon atoms of the sonicated fluorinated graphite, finally creating covalently bonded sulfur chains on the graphene surface. This procedure leads to high sulfur loading and bonding, inhibiting the “shuttle effect”, while the presence of graphene offers conductive paths for electron transfer in the battery cell.
The sulfur functionalized graphene has thus desirable features enabling its use as a high sulfur containing cathode without the drawbacks for materials known in the art. In particular, its high sulfur loading which is combined with the covalent bonding of sulfur on the graphene's surface, leads to a high specific capacity and high cycling stability, which is comparable or higher than previous sulfur-containing graphene-based LSB materials, according to the prior art. The highest achieved value of specific capacity as described in the Example 7 was 912 mAh g−1.
The sulfur functionalized graphene which is obtained by the method of the present invention contains covalently bonded sulfur and has a sulfur loading of at least 60 wt. %, preferably of at least 70 wt. %. The sulfur loading is determined by thermogravimetric analysis by measuring the weight loss in the temperature range of 200-350° C. The sulfur functionalized graphene further contains residual fluorine and sodium.
In other words, the sulfur functionalized graphene contains covalently bonded sulfur in a proportion of at least 12 at. %, and residual fluorine and sodium which are optionally in a proportion of up to 10 at. %. The at. % are determined relative to the total atoms present in the sample and are determined by X-ray photoelectron spectroscopy (XPS) using an Al—Kα source.
Preferably the sulfur functionalized graphene contains at least 18 at. % of sulfur, up to 8 at. % of fluorine and up to 9 at. % of sodium, relative to the total atoms present in the sample and determined by X-ray photoelectron spectroscopy (XPS) using an Al—Kα source.
The content of sulfur in the sulfur-functionalized graphene with the present method of production could peak approximately around 18.4 at. %, relative to the total atoms present in the sample and determined by X-ray photoelectron spectroscopy (XPS) using an Al—Kα source. This sulfur content corresponds to a mass content of 80 wt %, according to thermogravimetric analysis, as described in Example 2.
Another aspect of the present invention is the use of the sulfur functionalized graphene described above as a LSB cathode material. The sulfur functionalized graphene of the present invention possesses a high specific capacity, a very high retention of the capacity upon cycling at both low and high current rates.
The invention also provides an electrical cell comprising at least two electrodes, a separator and an electrolyte, wherein one electrode contains or consists of the sulfur functionalized graphene described above.
The electrolyte can be a liquid electrolyte containing a lithium salt.
The electrical cell may contain at least two electrodes, wherein at least one electrode is made of the sulfur functionalized graphene of the present invention applied on a current collector (such as a carbon coated aluminium foil), at least one separator membrane provided between the electrodes, the separator membrane(s) being soaked by an electrolyte, and a lithium foil anode.
In a particular embodiment, a two-electrode system using a lithium foil as anode was used to evaluate the performance, rate capability and cyclic stability of the sulfur functionalized graphene obtained from step (e). The sulfur functionalized graphene was homogeneously dispersed in N-methyl-2-pyrrolidone (NMP) adding poly-vinyl fluoride (PVDF) and carbon black (Ketjen black), preferably at a mass ratio of 90:5:5, and sonicated, preferably for 6 hours, to form a homogenous paste. Moreover, during sonication every 2 hours the slurry was mixed in a planetary mixer to better distribute the components. The slurry was pasted on an aluminum foil via doctor blading (180 μm blade height). Next, the film was dried at 80° C. in a vacuum oven overnight, and then two electrodes were cut into 18 mm discs. Afterwards, the mass of the electrodes were measured and dried again at 80° C. under vacuum (40 mbar), preferably for 8 hours in a vacuum oven. The electrodes were transferred (under vacuum) to an Ar filled glovebox. The cathode electrode and the lithium foil were placed face-to-face with a separator membrane in between. The separator membrane was soaked with the selected electrolyte. The electrodes were enclosed in an air-tight packaging and the current collectors were connected with the testing equipment (the battery tester). Before actual testing of the battery cell, conditioning was performed by resting the electrodes until reaching the open-circuit voltage (Eoc) equilibrium (around 6 hours) and then charging the cell at voltages lower than the final voltage used, and at lower specific currents.
Graphite fluoride (>61 wt % F), Na2S.9H2O, Sulfur and 1-Methyl-2-pyrrolidinone anhydrous, 99.5% were purchased from Sigma-Aldrich. Acetone (pure) and ethanol (absolute) were purchased from Penta, Czech Republic. All chemicals were used without further purification.
FT-IR spectra were measured on an iS5 FTIR spectrometer (Thermo Nicolet), using the KBr pellet accessory. Spectra were recorded by summing 50 scans, using pure KBr for the background acquisition. X-ray photoelectron spectroscopy (XPS) was performed on a PHI VersaProbe II (Physical Electronics) spectrometer, using an Al—Kα source (15 kV, 50 W). MultiPak (Ulvac—PHI, Inc.) software package was used for deconvolution of obtained data.
The samples were also analyzed with scanning electron microscopy using Hitachi SU6600 instrument with accelerating voltage of 5 kV. For these analyses, an electrode or a small droplet of a material dispersion in ethanol (concentration approximately 0.1 mg ml−1) was placed on a carbon-coated copper grid and left for drying.
Thermal analysis was performed with an STA449 C Jupiter Netzsch instrument.
Cyclic voltammetry (CV) and Galvanostatic Charge-Discharge with Potential Limitation (GCPL) were performed on a Bio-Logic battery tester (BCS-810) controlled with the BT-Lab software (version 1.64).
The following passage defines the battery metrics which are used in the present document, and generally accepted in the field. Specific capacity (C in mAh g−1) of the electrode material is calculated from galvanostatic charge-discharge curves according to the equations:
The capacity was calculated with respect to the sulfur mass as it was measured through the TGA.
The coulombic efficiency (CE %) for each cycle is calculated according to the equation:
The C-rate is calculated from the sulfur theoretical capacity (1672 mAh g−1), meaning that at 1 C (0.17 A g−1) a fully charged battery rated at 1 Ah should provide 1 A for one hour with respect to the sulfur mass. The current densities are calculated with respect to the sulfur mass and given in A g−1.
In a glass spherical flask. 4.8 g of sodium sulfide nonahydrate (Na2S.9H2O) was dissolved in 20 ml water-ethanol mixed solvent (1:1 volume ratio) and 0.64 g of sulfur (S) was added subsequently. The solution was stirred with a teflon coated magnetic bar for 3 hours at 30° C. and turned from yellow to dark orange indicating the gradually increasing chain length of the polysulfides. The solvent was vacuum dried in a rotary evaporator (30° C.) and the residue was milled in a mortar to create a fine powder.
X-ray photoelectron spectroscopy on the product of Example 1 (
To prepare the sulfur functionalized graphene (GPS), firstly 250 mg of graphite fluoride was dispersed in 15 ml of NMP using a 50 ml glass spherical flask. The flask was covered and left stirring for 3 days. Then, it was sonicated for 4 hours to achieve better exfoliation. After the exfoliation, 2 g of the product from Example 1 was added and the mixture reacted at 80° C. in an oil bath under reflux for 48 h, in N2 atmosphere, using magnetic stirring with teflon coated magnetic bar. After the end of the reaction, the mixture was left to cool down and transferred to 50 ml falcon centrifuge tubes. The solid particles (the product) were separated from the solvent and the by-products by centrifugation at 15000 ref for ca. 10 minutes. The supernatant was discarded, and the tube was refilled with the next washing solvent. The sample was homogenized by shaking and sonication for at least 1 minute, in order to redisperse the precipitate in the new solvent. Washing was performed with different solvents: NMP (3×), acetone (3×), ethanol (3×), and distilled water (3×), then refilled back with distilled water. Finally, the aqueous mixture was frozen at −80° C. and after 3 hours it was inserted in a freeze dryer (−108° C., 0.4 mbar) for 2 days. The final product was a fine powder.
X-ray photoelectron spectroscopy on the starting Fluorographite (FG) and on the product of Example 2 (
The actual sulfur content for each example was determined via, thermogravimetric analysis (TGA) where the weight loss in the temperature range of 200-350° C. is due to the release and evaporation of sulfur (
FT-IR analysis was performed to understand better the chemical structure of the materials. The defluorination of the starting FG after the reaction and isolation of the product (GPS) and the presence of C—S covalent bonds were verified. The C—F band (˜1200 cm−1) decreased and a new band at ˜1570 cm−1 emerged indicating the successful defluorination and the formation of C═C bonds (aromatic ring stretching), respectively (
The same procedure as in Example 2 was followed, but instead of heating the mixture at 80° C. for 48 h, it was heated at 50° C. for 48 h.
Thermogravimetric analysis (TGA) was performed to verify the sulfur loading in this example (
The same procedure as in Example 2 was followed, but instead of heating the mixture at 80° C. for 48 h, was left at room temperature for 48 h.
Thermogravimetric analysis (TGA) was performed to verify the sulfur loading in this example (
The same procedure as in Example 2 was followed, but FG was heat-treated for 48 h in absence of the product from Example 1 (the polysulfides). Firstly 250 mg of graphite fluoride was dispersed in 15 ml of NMP using a 50 ml glass spherical flask. The flask was covered and left stirring for 3 days. Then, it was sonicated for 4 hours to achieve better exfoliation. Then heating in NMP at 120° C. for 48 h took place without adding sodium polysulfide. The product of this reaction was significantly &fluorinated and contained only 15 at % of fluorine. After these 48 h of heating, the sodium polysulfide was added and the mixture was heated at 80° C. for 48 h. Thermogravimetric analysis (TGA) was performed to verify the sulfur loading in this example (
The same procedure as in Example 2 was followed, but instead of using 2 g of PS, 1 g was used in order to lower the FG/PS mass ratio in the reaction from 1:8 (Example 2) to 1:4.
Thermogravimetric analysis (TGA) was performed to verify the sulfur loading in this example (
The active material (sulfur functionalized graphene, UPS, from Example 2) was homogeneously dispersed in N-methyl-2-pyrrolidone (p.a.≥99%, Sigma-Aldrich) with binder Polyvinylidene fluoride (PVDF, Sigma-Aldrich) and conductive carbon Ketjen black (AkzoNobel) at a ratio of 90:5:5 and sonicated for 6 hours, to form a homogenous paste. Moreover, during sonication every 2 hours the slurry was mixed in a planetary mixer (Thinky ARV-310LED) to better distribute the components. The slurry was pasted on a carbon-coated aluminium foil (Cambridge Energy Solutions, thickness 15 μm) with doctor's blade technique (Erichsen, Quadruple Film Applicator, Model 360). Next, the film was dried at 80° C. in vacuum oven overnight, before electrodes with a diameter of 18 mm were cut. The obtained film was examined with scanning electron microscopy before testing, showing the sulfur particles covering the uniformly distributed graphene sheets while being attached on them (
Before testing the device, conditioning of the electrode materials was performed as follows:
Rest the electrode until it reaches voltage equilibrium (usually ˜6 hours) and hold of potential for 3 hours at 1.5 V.
The above mentioned cells were tested via cyclic voltammetry (CV), and charge/discharge profiling. Firstly, the CV profiles were recorded in 0.1, 0.2 and 0.5 mV s−1. In all cases, the anodic peak during charge is ascribed to the oxidation of the cathode which is completed in two stages, with the broad peak at ˜2.45 V representing the conversion of Li2S1-2to Li2Sn (n>2) and the formation of elemental sulfur. The reduction is also completed in two clearly separated steps: The peak at 2.25 V is ascribed at the reduction of elemental sulfur to LiSn(4≤n≤8) while the peak at 1.8 V corresponds to the subsequent reduction of LiSn to Li2S1-2 (
The same procedure as in Example 6 was followed, but instead of using the product of Example 2, the product of Example 6 was used. Li foil was used as anode and 1 M of LiTFSI (lithium bis-trifluoromethanesulfonimide, MTI) in a 1:1 mixture of DOL (Dioxolane, Aldrich) and TTE (1,1,2,2-Tetrafluoroethyl 2,2,3,3-Tetrafluoropropyl Ether, TCI) was used as electrolyte. Before testing the device, conditioning of the electrode materials was performed as follows: Rest the electrode until it reaches voltage equilibrium (usually ˜6 hours) and hold of potential for 3 hours at 1.5 V.
The stability testing of this material shows good results in low current density. The initial capacity was 686 mA g−1 at 0.2 C (0.33 A g−1) and the cell maintained very high stability even this rate showing 784 mAh g−1 after 100 cycles (
| Number | Date | Country | Kind |
|---|---|---|---|
| 20199904.2 | Oct 2020 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CZ2021/050045 | 5/4/2021 | WO |
