1. Field of the Invention
This invention generally relates to electrochemical batteries and, more particularly, to a water-soluble binder for use with a transition. metal hexacyanometallate electrode.
2. Description of the Related Art
Transition metal cyanometallates (TMCMs) with large interstitial spaces have been investigated as the cathode material for rechargeable lithium-ion batteries [1, 2], sodium-ion batteries [3, 4], and potassium-ion batteries [5]. With an aqueous electrolyte containing the proper alkali-ions or ammonium-ions, copper and nickel hexacyanoferrates ((Cu,Ni)-HCFs) exhibited a very good cycling life with 83% capacity retained after 40,000 cycles at a charge/discharge current of 17 C (1 C=150 milliamps per gram) [6-8]. However, the materials within the aqueous electrolyte demonstrated low capacities and energy densities because: (1) just one sodium-ion can be inserted/extracted into/from per Cu-HCF or Ni-HCF formula, and (2) these transition metal cyanoferrate (TM-HCF) electrodes must be operated below 1.23 V due to the water electrochemical window. The electrochemical window of a substance is the voltage range between which the substance is neither oxidized nor reduced. This range is important for the efficiency of an electrode, and once out of this range, water becomes electrolyzed, spoiling the electrical energy intended for another electrochemical reaction.
To correct these shortcomings, manganese hexacyanoferrate (Mn-HCF) and iron hexacyanoferrate (Fe-HCF) were used as cathode materials in non-aqueous electrolyte [9, 10]. Assembled with a sodium-metal anode, Mn-HCF and Fe-HCF electrodes cycled between 2.0V and 4.2 V and delivered capacities of about 150 mAh/g.
Unlike conventional lithium-ion battery cathode materials, TMHCF can be easily prepared via precipitation in water, and does not require further high-temperature treatment. Parent applications Ser. Nos. 62/008,869 and 14/067,038, among others, describe exemplary precipitation synthesis, and are incorporated herein by reference. For example, Na2MnFe(CN)6 can be easily made by mixing two water solutions containing Na4Fe(CN)6 and MnCl2, which are subsequently filtered and dried at 100° C. Such an aqueous solution-based synthesis route provides an as-prepared TMHCF chemical having good stability and dispersion capability in water. Thus, TMHCM has a significantly lower synthesis cost as compared with the cathode materials used for lithium-ion batteries (LIBs). The low material cost of TMHCM makes it a very promising cathode material for stationary energy storage batteries, but the fabrication costs need to be cut even further to make it a truly viable battery option. Polyvinylidene fluoride (PVDF) is used as a standard binder for cathode electrode in LIBs because of its good adhesion and electrochemical stability. However, harmful organic solvents, like N-Methyl-2-pyrrolidone (NMP), are used to dissolve PVDF during the electrode coating process. A solvent recycling system is therefore required for cost and environment concerns. Thus, a high fabrication cost is associated with the conventional PVDF binder.
In contrast, a water-soluble binder is relatively inexpensive, process preferable, and environment friendly, all of which makes it a desirable binder for use in energy storage batteries. Although the substitution of PVDF with a water-soluble binder like carboxymethylcellulose (CMC) in LIBs has been investigated, challenges remain because the electrochemical performance of lithium transition metal oxides are compromised from dissolution or poor dispersion capability when aqueous binders are used. The electrode materials for lithium-ion batteries are prepared using high temperature calcinations, and problems typically occur when they are put into a water solution during electrode fabrication. For example, an ion-exchange reaction occurs between proton and lithium ions when LiMn2O4 is put into water. In other examples, the dissolution of active materials is observed when a LiNi1/3Co1/3Mn1/3O2 electrode is processed in an aqueous solution, and poor adhesion between LiFePO4 electrode and the current collector also hinders using water-soluble binders for battery fabrication.
It would be advantageous if a high quality electrode could be fabricated, with transition metal hexacyanometallate (TMHCM) as an active material and an aqueous binder, for use in sodium-ion batteries (SIBs) or other rechargeable metal-ion batteries.
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[3] Y. Lu, L. Wang, J. Cheng, J. B. Goodenough, Prussian blue: a new framework for sodium batteries, Chemistry Communication, 48(2012)6544-6546.
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[8] C. D. Wessels, S. V. Peddada, M. T. McDowell, R. A. Huggins, Y. Cui, The effect of insertion species on nanostructured open framework hexacyanoferrate battery electrode, J. Electrochem. Soc., 159(2012) A98-A103.
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[10] S. -H. Yu, M. Shokouhimehr, T. Hyeon, Y. -E. Sung, Iron hexacyanoferrate nanoparticles as cathode materials for lithium and sodium rechargeable batteries, ECS Electrochemistry Letters, 2(2013)A39-A41.
Disclosed herein is an electrode comprising transition metal hexacyanometallates (TMHCMs) as an active material and a water-soluble binder. The electrode can serve either as a cathode or an anode in a rechargeable using metal-ions such as lithium (Li+), ammonium (NH4+), sodium (Na+), potassium (K+), magnesium (Mg2+), aluminum (Al3+), cesium (Cs+), rubidium (Rb+), zinc (Zn2+), barium (Ba2+), strontium (Sr2+), or calcium (Ca2+) battery. The water-soluble binder may be poly(acrylonitrile-co-acrylamide)polymer, carboxymethylcellulose (CMC), poly vinyl alcohol, polyvinylpyrrolidone, poly acrylic acid, polymethacrylic acid, polyethylene oxide, polyacrylamide, poly-N-isopropylacrylamide, Poly-N,N-dimethylacrylamide, polyethyleneimine, polyoxyethylene, polyvinylsulfonic acid, poly(2-methoxyethoxyethoxyethylene), styrene butadiene rubber (SBR), butadiene-acrylonitrile, rubber (NBR), hydrogenated NBR (HNBR), epichlorhydrin rubber (CHR), acrylate rubber (ACM), poly(allylamine), xanthan gum, guar gum, chitosan, polyvinyl acetate, gelatin, casein. The water-soluble binder may be natural cellulose, physically and/or chemically modified cellulose, natural polysaccharides, chemically and/or physically modified polysaccharides, hydroxy methyl cellulose or methyl ethyl hydroxy cellulose. The water-soluble binder may also be a poly(carboxylic acid), some examples of which include polylactic acid (PLA), polyacrylic acid, polysuccinic acid, poly maleic acid and anhydride, poly furoic (pyromucic acid), poly fumaric acid, poly sorbic acid, poly linoleic acid, poly linolenic acid, poly glutamic acid, poly methacrylic acid, poly licanic acid, poly glycolic acid, poly aspartic acid, poly amic acid, poly formic acid, poly acetic acid, poly propoionic acid, poly butyric acid, poly sebacic acid, and copolymers thereof.
Also provided is a method of fabricating such an electrode with an aqueous solution. A slurry comprising TMHCM and a binder selected from the aforementioned examples is formed and coated onto a metal (e.g., aluminum, copper, nickel, etc.) or carbon current collector. The binder can be either completely or partially dissolved into water.
Accordingly, the method for fabricating the TMHCM electrode with a water-soluble binder initially forms an electrode mix slurry comprising TMHCF and a water-soluble binder. The electrode mix slurry is applied to a current collector, and then dehydrated to form an electrode. The electrode mix slurry may additionally comprise a carbon additive such as carbon black, carbon fiber, carbon nanotubes, graphite, or graphene.
The electrode is typically formed with TMHCM greater than 50%, by weight, as compared to a combined weight of the TMHCM, carbon additive, and binder.
Additional details of the above-described method, a TMHCM electrode made with a water-soluble binder, and battery made using such an electrode as the cathode are provided below.
Some examples of the water-soluble material 106 include poly(acrylonitrile-co-acrylamide)polymer, carboxymethylcellulose (CMC), poly vinyl alcohol, polyvinylpyrrolidone, poly acrylic acid, polymethacrylic acid, polyethylene oxide, polyacrylamide, poly-N-isopropylacrylamide, Poly-N,N-dimethylacrylamide, polyethyleneimine, polyoxyethylene, polyvinylsulfonic acid, poly(2-methoxyethoxyethoxyethylene), styrene butadiene rubber (SBR), butadiene-acrylonitrile, rubber (BR), hydrogenated NBR (HNBR), epichlorhydrin rubber (CHR), acrylate rubber (ACM), poly(allylamine), xanthan gum, guar gum, chitosan, polyvinyl acetate, gelatin, casein, cellulose, and poly(carboxylic acid).
Some explicit examples of cellulose include natural cellulose, physically modified cellulose, chemically modified cellulose, natural polysaccharides, chemically modified polysaccharides, physically modified polysaccharides, hydroxy methyl cellulose, and methyl ethyl hydroxy cellulose. Some explicit examples of poly(carboxylic acid) include polylactic acid (PLA), polyacrylic acid, polysuccinic acid, poly maleic acid and anhydride, poly furoic (pyromucic acid), poly fumaric acid, poly sorbic acid, poly linoleic acid, poly linolenic acid, poly glutamic acid, poly methacrylic acid, poly licanic acid, poly glycolic acid, poly aspartic acid, poly amic acid, poly formic acid, poly acetic acid, poly propoionic acid, poly butyric acid, poly sebacic acid, and copolymers thereof.
Lithium is a common choice as an active material in conventional batteries. Lithium compounds are conventionally prepared with non-aqueous binders such as PVDF. As noted above, an ion-exchange occurs when these conventional lithium compounds react with water, causing dissolution and adhesion problems. Advantageously, since TMHCM materials are prepared in water, the use of a water-soluble binder does not create the compatibility issues associated with the use of lithium compounds. TMHCM is stable and dispersed easily in water. Since TMHCM materials share many of the same characteristics as conventional lithium compounds, the prevalent thinking in the industry has been to make TMHCM electrodes using many of the same processes as lithium batteries, including the use of non-aqueous binders. Thus, although the use of water-soluble binders is not unheard of, it is new to the application of TMHCM electrodes.
The TMHCM active material 104 of electrode 100 is typically greater than 50%, by weight, as compared to a combined weight of the TMHCM active material 104, carbon additive 108, and binder 106. The TMHCM active material 104 is expressed by the formula ANM1PM2Q(CN)R .FH2O;
Some explicit examples of the metals that comprise the “A” element include lithium (Li), sodium (Na), potassium (K), rubidium (Rb), cesium (Cs), calcium (Ca), strontium (Sr), barium (Ba), silver (Ag), aluminum (Al), magnesium (Mg), and combinations thereof, Some explicit examples of M1 and M2 metals include titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), niobium (Nb), ruthenium (Ru), tin (Sn), indium (In), cadmium (Cd), Ca, magnesium (Mg), strontium (Sr), and barium (Ba).
Some examples of transitions metals from which M1 and M2 are each independently selected include titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), niobium (Nb), ruthenium (Ru), tin (Sn), indium (In), cadmium (Cd), Ca, Mg, strontium (Sr), and barium (Ba).
As noted above in the description of
where “A” is selected from a first group of metals that include alkali and alkaline earth metals;
where M1 and M2 are independently selected from a second group of transition metals;
The anode 202 may be made from carbonaceous materials, alkali metals, alkaline earth metals, alloys including tin, alloys including lead, alloys including silicon, alloys including phosphorous, alloys including germanium, titanates including alkali metals, titanates including alkaline earth metals, and combinations thereof. The materials that may be used as the water-soluble binder are listed above in the description of
Some potential liquid electrolytes 204 include dimethyl carbonate and diethyl carbonate, ethylene carbonate, propylene carbonate, dimethoxy ethane, and ethylmethyl carbonate. Some potential polymer (gel) electrolytes 204 include poly(ethylene oxide) (PEO), poly(acrylonitrile) (PAN), poly(methyl metacrylate) (PMMA), polyvinyl chloride) (PVC), poly(vinylidene fluoride) (PVdF), and polyethylene (PE).
Electrodes, especially cathodes, in lithium-ion batteries (LIBs) use a conventional polyvinylidene fluoride (PVDF) as a binder that results in high material and fabrication cost. Moreover, the use of N-Methyl-2-pyrrolidone (NMP) as solvent during the electrode coating process has a strong impact on the environment. However, due the stability and dispersing capability of TMHCM in an aqueous solution, it is possible to fabricate such an electrode in a cheap, fast, and environment friendly process. Electrodes, fabricated using a doctor blade casting method with a slurry of PVDF binder and NMP solvent, were employed as the baseline for comparison. Excellent rate capability and good mechanical properties were obtained from electrodes made from Na2MnFe(CN)6 and water-soluble binders (CMC and SBR). The electrodes were coated onto an aluminum foil with an aqueous slurry. The electrode made with the water solution did not negatively impact battery performance when used as a cathode in a sodium battery. Electrodes with other TMHCMs and water-soluble binders can be prepared with similar manner and used in other rechargeable metal-ion batteries.
Step 602 forms an electrode mix slurry comprising TMHCF and a water-soluble binder. Step 604 applies the electrode mix slurry to a current collector. Step 606 dehydrates the electrode mix to form an electrode. In one aspect, forming the electrode mix slurry in Step 602 includes the electrode mix slurry additionally comprising a carbon additive such as carbon black, carbon fiber, carbon nanotubes, graphite, or graphene. Typically, the electrode is formed with TMHCM greater than 50%, by weight, as compared to a combined. weight of the TMHCM, carbon additive, and binder, after all the water has been removed in Step 606.
The water-soluble material may be poly(acrylonitrile-co-acrylamide)polymer, carboxymethylcellulose (CMC), poly vinyl alcohol, polyvinylpyrrolidone, poly acrylic acid, polymethacrylic acid, polyethylene oxide, polyacrylamide, poly-N-isopropylacrylamide, Poly-N,N-dimethylacrylamide, polyethyleneimine, polyoxyethylene, polyvinylsulfonic acid, poly(2methoxyethoxyethoxyethylene), styrene butadiene rubber (SBR), butadiene-acrylonitrile, rubber (NBR), hydrogenated NBR (HNBR), epichlorhydrin rubber (CHR), acrylate rubber (ACM), poly(allylamine), xanthan gum, guar gum, chitosan, polyvinyl acetate, gelatin, casein, cellulose, or poly(carboxylic acid).
Some examples of cellulose include natural cellulose, physically modified cellulose, chemically modified cellulose, natural polysaccharides, chemically modified polysaccharides, physically modified polysaccharides, hydroxy methyl cellulose, and methyl ethyl hydroxy cellulose. Some examples of poly(carboxylic acid) include polylactic acid (PIA), polyacrylic acid, polysuccinic acid, poly maleic acid and anhydride, poly furoic (pyromucic acid), poly fumaric acid, poly sorbic acid, poly linoleic acid, poly linolenic acid, poly glutamic acid, poly methacrylic acid, poly licanic acid, poly glycolic acid, poly aspartic acid, poly amic acid, poly formic acid, poly acetic acid, poly propoionic acid, poly butyric acid, poly sebacic acid, and copolymers thereof.
A TMHCM electrode made with a water-soluble binder has been presented. Examples of particular materials and process steps have been provided 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.
This application is a Continuation-in-Part of an application entitled, ELECTROLYTE ADDITIVES FOR TRANSITION METAL CYANOMETALLATE ELECTRODE STABILIZATION, invented by Yuhao Lu et al, Ser. No. 14/320,352, filed Jun. 30, 2014, attorney docket No. SLA3431; Ser. No. 14/320,352 claims the benefit of a Provisional application entitled, HARD CARBON COMPOSITE FOR ALKALI METAL-ION BATTERIES, invented by Yuhao Lu et al, Ser. No. 62/009,069, filed Jun. 6, 2014, attorney docket No. SLA3416P; Ser. No. 14/320,352 claims the benefit of a Provisional application entitled, METAL CYANOMETALLATE SYNTHESIS METHOD, invented by Long Wang et al, Ser. No. 62/008,869, filed Jun. 6, 2014, attorney docket No. SLA3430P; Ser. No. 14/320,352 is a Continuation-in-Part of an application entitled, RECHARGEABLE METAL-ION BATTERY WITH NON-AQUEOUS HYBRID ION ELECTROLYTE, invented by Long Wang et al, Ser. No. 14/271,498, filed May 7, 2014, attorney docket No. SLA3388; which is a Continuation-in-Part of an application entitled, REACTIVE SEPARATOR FOR A METAL-ION BATTERY, invented by Long Wang et al, Ser. No. 14/230,882, filed Mar. 31, 2014, attorney docket No. SLA3370; which is a Continuation-in-Part of an application entitled, NASICON-POLYMER ELECTROLYTE STRUCTURE, invented by Long Wang et al, Ser. No. 14/198,755, filed Mar. 6, 2014, attorney docket No. SLA3367; which is a Continuation-in-Part of an application entitled, BATTERY WITH AN ANODE PRELOADED WITH CONSUMABLE METALS, invented by Yuhao Lu et al, Ser. No. 14/198,702, filed Mar. 6, 2014, attorney docket No. SLA3364; which is a Continuation-in-Part of an application entitled, BATTERY ANODE WITH PRELOADED METALS, invented by Long Wang et al, Ser. No. 14/198,663, filed Mar. 6, 2014, attorney docket No. SLA3363; which is a Continuation-in-Part of an application entitled, METAL BATTERY ELECTRODE WITH PYROLYZED COATING, invented by Yuhao Lu et al, Ser. No. 14/193,782, filed Feb. 28, 2014, attorney docket No. SLA3353; which is a Continuation-in-Part of an application entitled, METAL HEXACYANOMETALLATE ELECTRODE WITH SHIELD STRUCTURE, invented by Yuhao Lu et al, Ser. No. 14/193,501, filed Feb. 28, 2014, attorney docket No. SLA3352; which is a Continuation-in-Part of an application entitled, CYANOMETALLATE CATHODE BATTERY AND METHOD FOR FABRICATION, invented by Yuhao Lu et al, Ser. No. 14/174,171, filed Feb. 6, 2014, attorney docket No. SLA3351; This application is a Continuation-in-Part of an application entitled, SODIUM IRON(II)-HEXACYANOFERRATE(II) BATTERY ELECTRODE AND SYNTHESIS METHOD, invented by Yuhao Lu et al, Ser. No. 14/067,038, filed Oct. 30, 2013, attorney docket No. SLA3315; which is a Continuation-in-Part of an application entitled, TRANSITION METAL HEXACYANOMETALLATE-CONDUCTIVE POLYMER COMPOSITE, invented by Sean Vail et al., Ser. No. 14/059,599, filed Oct. 22, 2013, attorney docket No. SLA3336; which is a Continuation-in-Part of an application entitled, METAL-DOPED TRANSITION METAL HEXACYANOFERRATE (TMHCF) BATTERY ELECTRODE, invented by Yuhao Lu et al., Ser. No. 13/907,892, filed Jun. 1, 2013, attorney docket No. SLA3287; which is a Continuation-in-Part of an application entitled, HEXACYANOFERRATE BATTERY ELECTRODE MODIFIED WITH FERROCYANIDES OR FERRICYANIDES, invented by Yuhao Lu et al., Ser. No. 13/897,492, filed May 20, 2013, attorney docket No. SLA3286; which is a Continuation-in-Part of an application entitled, PROTECTED TRANSITION METAL HENACYANOFERRATE BATTERY ELECTRODE, invented by Yuhao Lu et al., Ser. No. 13/872,673, filed Apr. 29, 2013, attorney docket No. SLA3285; which is a Continuation-in-Part of an application entitled, TRANSITION METAL HENACYANOFERRATE BATTERY CATHODE WITH SINGLE PLATEAU CHARGE/DISCHARGE CURVE, invented by Yuhao Lu et al., Ser. No. 13/752,930, filed Jan. 29, 2013, attorney docket No. SLA3265; which is a Continuation-in-Part of an application entitled, SUPERCAPACITOR WITH HEXACYANOMETALLATE CATHODE, ACTIVATED CARBON ANODE, AND AQUEOUS ELECTROLYTE, invented by Yuhao Lu et al., Ser. No. 13/603,322, filed Sep. 4, 2012, attorney docket No. SLA3212. Ser. No. 13/752,930 is also a Continuation-in-Part of an application entitled, IMPROVEMENT OF ELECTRON TRANSPORT IN HEXACYANOMETALLATE ELECTRODE FOR ELECTROCHEMICAL APPLICATIONS, invented by Yuhao Lu et al., Ser. No. 13/523,694, filed Jun. 14, 2012, attorney docket No. SLA3152; which is a Continuation-in-Part of an application entitled, ALKALI AND ALKALINE-EARTH ION BATTERIES WITH HEXACYANOMETALLATE CATHODE AND NON-METAL ANODE, invented by Yuhao Lu et al., Ser. No. 13/449,195, filed Apr. 17, 2012, attorney docket no. SLA3151; which is a Continuation-in-Part of an application entitled, ELECTRODE FORMING PROCESS FOR METAL-ION BATTERY WITH HEXACYANOMETALLATE ELECTRODE, invented by Yuhao Lu et al., Ser. No. 13/432,993, filed Mar. 28, 2012, attorney docket no. SLA3146, All these applications are incorporated herein by reference.
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