(12) United States Patent (10) Patent No.: US 8,715,853 B1 Vajo Et Al

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(12) United States Patent (10) Patent No.: US 8,715,853 B1 Vajo Et Al US008715853B1 (12) United States Patent (10) Patent No.: US 8,715,853 B1 Vajo et al. (45) Date of Patent: May 6, 2014 (54) ALUMINUM BATTERIES COMPRISING 200 Fs: R ck 1858 R et al. 429.218.1 METAL-OXIDE, METAL-FLUORIDE, ck all . METAL-SULFIDE, OR SULFUR CATHODES 2011/O143202 A1 6/2011 Farmer et al. .............. 429.218.1 OTHER PUBLICATIONS (75) Inventors: John J. Vajo, West Hills, CA (US); Donahue et al., “Secondary aluminum-iron (III) chloride batteries Adam F. Gross, Santa Monica, CA with a low temperature molten salt electrolyte.” J. Applied Electro (US); Ping Liu, Irvine, CA (US); chemistry 22 (1992), 230-234, Chapman & Hall. Jocelyn Hicks-Garner, Venice, CA Li and Bjerrum, "Aluminum as anode for energy storage and conver (US); Elena Sherman, Culver City, CA sion: a review.” Journal of Power Sources 110 (2002), 1-10, Elsevier (US); Sky Van Atta, Culver City, CA Science B.V. (US) Santiso et al., “Adsorption and catalysis: the effect of confinement on chemical reactions' Applied Surface Science 252 (2005) 766-777. Liu et al., “Controlling the decomposition pathway of LiBH4 via (73) Assignee: HRL Laboratories, LLC, Malibu, CA confinement in highly ordered nanoporous carbon' J. Physical (US) Chemistry C 114 (2010) 14030-14041. Bruce et al., “Nanomaterials for rechargeable lithium batteries' (*) Notice: Subject to any disclaimer, the term of this Angew. Chem. Int. Ed. 47 (2008) 2930-2946. patent is extended or adjusted under 35 Arico et al., “Nanostructured materials for advanced energy conver sion and storage devices' Nature Materials 4 (2005) 366-377. U.S.C. 154(b) by 438 days. Ji et al., “A highly ordered nanostructured carbon-Sulphur cathode for lithium–sulphur batteries' Nature Materials 8 (2009) 500-506. (21) Appl. No.: 12/868,479 * cited by examiner (22) Filed: Aug. 25, 2010 Primary Examiner — Jane Rhee (51) Int. Cl. (74) Attorney, Agent, or Firm — O'Connor & Company HOLM 4/02 (2006.01) (52) U.S. Cl. (57) ABSTRACT USPC ........... 429/209; 429/200; 429/219; 429/220; Variations of the invention provide an improved aluminum 429/221; 429/223 battery consisting of an aluminum anode, a non-aqueous (58) Field of Classification Search electrolyte, and a cathode comprising a metal oxide, a metal CPC ................................ H01 M 4/00; H01M 4/463 fluoride, a metal sulfide, or sulfur. The cathode can be fully USPC . 429/200, 209, 221, 220, 223, 219 reduced upon battery discharge via a multiple-electron reduc See application file for complete search history. tion reaction. In some embodiments, the cathode materials are contained within the pore Volume of a porous conductive (56) References Cited carbon scaffold. Batteries provided by the invention have U.S. PATENT DOCUMENTS high active material specific energy densities and good cycling stabilities at a variety of operating temperatures. 4,882.244. A * 1 1/1989 Donahue et al. .............. 429,339 6,316,142 B1 1 1/2001 Delnicket al. 45 Claims, 2 Drawing Sheets CoF in carbon aerogel Commercial CoF 2O 30 40 50 60 Two Theta (degrees) U.S. Patent May 6, 2014 Sheet 1 of 2 US 8,715,853 B1 s O O O) (v. C O O O c O O : (Sun Wue Cue) WISueu U.S. Patent May 6, 2014 Sheet 2 of 2 US 8,715,853 B1 8 8 8 US 8,715,853 B1 1. 2 ALUMINUM BATTERIES COMPRISING In some variations, the invention provides an aluminum METAL-OXIDE, METAL-FLUORIDE, battery comprising an aluminum-containing anode, a non METAL-SULFIDE, OR SULFUR CATHODES aqueous electrolyte, and a cathode, wherein the cathode com prises one or more cathode active materials selected from the FIELD OF THE INVENTION group consisting of metal (M) oxides and metal (M) fluorides; and wherein the battery has a discharge state wherein the ratio The present invention generally relates to improved alumi of the number of Al atoms to the number of metal (M) atoms num batteries and novel cathodes for aluminum batteries. in the cathode is about 0.4 or greater. BACKGROUND OF THE INVENTION In various embodiments, the ratio of the number of Al 10 atoms to the number of metal (M) atoms in the cathode is Aluminum (Al) is an attractive anode material for energy about 0.6,0.8, 1.0, 1.2, or greater. storage and conversion. Its relatively low atomic weight of The cathode active material may be one or more metal 26.98 along with its trivalence give an electrochemical oxides selected from the group consisting of CuO, POs, equivalent of 2.98 Ah/g, compared with 3.86 Ah/g for lithium, SnO, PbO, Fe0, FeO, CoO, CoO, NiO, and AgO. Or, 2.20 Ah/g for magnesium, and 0.82 Ah/g for zinc. From a 15 the cathode active material may be one or more metal fluo Volume standpoint, aluminum should yield a capacity per unit rides selected from the group consisting of CoF CoF FeF. volume of 8.04 Ah/cm, compared with 2.06 Ah/cm for FeF, CuF, MoFs, and SnF. lithium, 5.85 Ah/cm for zinc, and 3.83 Ah/cm for magne In some embodiments, the non-aqueous electrolyte is a sium. Aluminum-based batteries, in principle, have better mixture of aluminum chloride and an organic salt selected chemical stability in many electrolytes than do lithium-based from the group consisting of n-butyl pyridinium chloride, batteries. Additionally, aluminum is an abundant and rela 1-methyl-3-ethylimidazolium chloride, 1,2-dimethyl-3-pro tively inexpensive metal. pylimidazolium chloride, 1,4-dimethyl-1,2,4-triazolium The state of the art includes many Albattery chemistries chloride, and any combinations thereof. based on aqueous electrolytes (see, for example, Li and Bjer Other variations of the invention provide an aluminum rum, "Aluminum as anode for energy storage and conversion: 25 battery comprising an aluminum-containing anode, a non a review.” Journal of Power Sources, vol. 110, pp. 1-10, aqueous electrolyte, and a cathode, the cathode comprising 2002). However, for all aqueous electrolyte-based Albatter ies, corrosion of the Al anode is a persistent problem. Corro (a) one or more cathode active materials selected from the sion of the anode reduces an Albattery’s energy content and group consisting of a metal (M) oxide, a metal (M) fluoride, a limits storage life. In addition, the corrosion products lead to metal (M) sulfide, and sulfur (represented here as M); and (b) passivating films that inhibit the battery reactions, thereby 30 a conductive material with pores having at least one dimen reducing the battery's power capabilities. sion below about one micrometer, wherein the cathode active Due to the problems associated with aqueous electrolytes, material is contained within the pores, wherein the battery has it is beneficial to employ non-aqueous molten salt electrolytes a discharge state wherein the ratio of the number of Al atoms in Al batteries. Compared with aqueous electrolytes, the to the number of M atoms in the cathode is about 0.4 or advantages of molten salts are mainly three-fold: high elec 35 greater. trical conductivity, fast electrode kinetics and hence less The ratio of the number of Al atoms to the number of M polarization, and high decomposition potential. Aluminum atoms in the cathode may be about 0.6,0.8, 1.0.1.2, or greater. can be electrodeposited from non-aqueous media and there In some embodiments, the conductive material includes a fore molten salt electrolytes are suitable for developing porous conductive scaffold, such as a porous conductive car rechargeable aluminum batteries. 40 bon scaffold. The state of the art includes Al batteries based on non In these variations, the cathode active material may be one aqueous molten salt electrolytes that operate near room tem or more metal oxides selected from the group consisting of perature (see, for example, Donahue et al., “Secondary alu CuO, POs, SnO, PbO2, FeC), FeO, CoO, Co-O, NiO, and minum-iron (III) chloride batteries with a low temperature AgO. Or, the cathode active material may be one or more molten salt electrolyte. Journal of Applied Electrochemistry, 45 metal fluorides selected from the group consisting of CoF vol. 22, pp. 230-234, 1992). The cathodes of these batteries contain transition-metal chlorides, such as FeCls, which react CoF FeF, FeF, CuF, MoFs, and SnF. The cathode active according to one-electron reduction reactions (e.g., material may be sulfur or a metal sulfide, such as FeS or FeCl+e=FeCl+Cl). As a result of the atomic weight of NiS. chlorine and the stoichiometry of the one-electron reduction Preferred aluminum batteries have an active material spe reaction, the theoretical active material specific energy den 50 cific energy density in excess of 400 Wh/kg, such as 800 sity of these batteries is less than 350 Wh/kg. This theoretical Wh/kg or higher. energy content is too low for many applications. The present invention additionally relates to novel cath In view of the current state of the art for Albatteries, there odes. In some variations, a cathode for an aluminum battery are several needs. First, Albatteries should effectively operate comprises one or more cathode active materials selected from at or near room temperature. Second, to reduce or avoid 55 the group consisting of metal oxides and metal fluorides, corrosion, Al batteries containing non-aqueous electrolytes wherein the cathode has a cathode discharge state wherein the are preferred. Third, improved Albatteries preferably include ratio of the total number of discharged electrons to the num a cathode that can be fully reduced upon battery discharge. ber of cathode metal atoms is greater than 1.0.
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