U.S. patent application number 14/092048 was filed with the patent office on 2014-03-20 for high capacity alkali/oxidant battery.
This patent application is currently assigned to Sharp Laboratories of America, Inc.. The applicant listed for this patent is Sharp Laboratories of America, Inc.. Invention is credited to David R. Evans, Hidayat Kisdarjono, Jong-Jan Lee, Yuhao Lu.
Application Number | 20140075745 14/092048 |
Document ID | / |
Family ID | 50272928 |
Filed Date | 2014-03-20 |
United States Patent
Application |
20140075745 |
Kind Code |
A1 |
Lu; Yuhao ; et al. |
March 20, 2014 |
High Capacity Alkali/Oxidant Battery
Abstract
An alkali/oxidant battery is provided with an associated method
of creating battery capacity. The battery is made from an anode
including a reduced first alkali metal such as lithium (Li), sodium
(Na), and potassium (K), when the battery is charged. The battery's
catholyte includes an element, in the battery charged state, such
as nickel oxyhydroxide (NiOOH), magnesium(IV) (oxide
Mn.sup.(4+)O.sub.2), or iron(III) oxyhydroxide
(Fe.sup.(3+)(OH).sub.3), with the alkali metal hydroxide. An alkali
metal ion permeable separator is interposed between the anolyte and
the catholyte. For example, if the catholyte includes nickel(II)
hydroxide (Ni(OH).sub.2) in a battery discharged state, then it
includes NiOOH in a battery charged state. To continue the example,
the anolyte may include dissolved lithium ions (Li.sup.+) in a
discharged state, with solid phase reduced Li formed on the anode
in the battery charged state.
Inventors: |
Lu; Yuhao; (Vancouver,
WA) ; Kisdarjono; Hidayat; (Vancouver, WA) ;
Lee; Jong-Jan; (Camas, WA) ; Evans; David R.;
(Beaverton, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sharp Laboratories of America, Inc. |
Camas |
WA |
US |
|
|
Assignee: |
Sharp Laboratories of America,
Inc.
Camas
WA
|
Family ID: |
50272928 |
Appl. No.: |
14/092048 |
Filed: |
November 27, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14042264 |
Sep 30, 2013 |
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14092048 |
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13564015 |
Aug 1, 2012 |
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14042264 |
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Current U.S.
Class: |
29/623.1 ;
429/101 |
Current CPC
Class: |
H01M 2/14 20130101; H01M
4/50 20130101; H01M 4/24 20130101; H01M 2004/028 20130101; H01M
4/52 20130101; Y02E 60/10 20130101; H01M 2300/0025 20130101; H01M
10/30 20130101; H01M 10/26 20130101; H01M 2300/0014 20130101; Y10T
29/49108 20150115; H01M 10/0525 20130101; H01M 2004/027 20130101;
H01M 8/188 20130101; Y02E 60/50 20130101; H01M 4/523 20130101; H01M
8/184 20130101; H01M 4/521 20130101; H01M 4/32 20130101; H01M
10/052 20130101; H01M 4/248 20130101; H01M 8/20 20130101; H01M
10/44 20130101; H01M 4/382 20130101; H01M 10/0568 20130101; H01M
12/08 20130101 |
Class at
Publication: |
29/623.1 ;
429/101 |
International
Class: |
H01M 4/52 20060101
H01M004/52; H01M 10/44 20060101 H01M010/44 |
Claims
1. An alkali/oxidant battery comprising: an anode including a
reduced first alkali metal in a battery charged state; an anolyte;
a cathode including an element, in the battery charged state,
selected from a group consisting of nickel oxyhydroxide (NiOOH),
magnesium(IV) oxide (Mn.sup.(4+)O.sub.2), and iron(III)
oxyhydroxide (Fe.sup.(3+)(OH).sub.3); a catholyte including a first
alkali metal hydroxide; and, a first alkali metal ion permeable
separator interposed between the anolyte and the catholyte.
2. The alkali/oxidant battery of claim 1 wherein the cathode
includes nickel(II) hydroxide (Ni(OH).sub.2) in a battery
discharged state and NiOOH in the battery charged state.
3. The alkali/oxidant battery of claim 2 wherein the anolyte
includes lithium ions (Li.sup.+) in the battery discharged
state.
4. The alkali/oxidant battery of claim 1 wherein the catholyte and
cathode are the same element, comprising a cathode slurry; and, the
cathode further comprising a cathode current collector submerged in
the cathode slurry.
5. The alkali/oxidant battery of claim 4 further comprising: a cell
comprising the anode, the anolyte, the first alkali metal ion
permeable separator, an input port and an output port; a cathode
slurry reservoir connected to the cell input and output ports to
supply an oxidized cathode slurry when the battery is electrically
discharging under load and a reduced cathode slurry when the
battery is being electrically charged.
6. The alkali/oxidant battery of claim 5 further comprising: a
plurality of cells connected in a configuration selected from a
group consisting of series and parallel electrical connections.
7. The alkali/oxidant battery of claim 6 wherein the cathode slurry
reservoir and the plurality of cells are connected in parallel to
transport the cathode slurry.
8. The alkali/oxidant battery of claim 1 wherein the anolyte in the
battery discharged state includes alkali metal ions selected from a
group consisting of lithium ions (Li.sup.+), sodium ions
(Na.sup.+), and potassium ions (K.sup.+); and, wherein the anode,
in the battery charged state, includes a solid phase reduced alkali
metal respectively selected from a group consisting of Li, Na, and
K, overlying a current collector.
9. The alkali/oxidant battery of claim 1 wherein the cathode
includes Mn.sup.(4+)O.sub.2 in the battery charged state and
magnesium (III) oxyhydroxide (Mn.sup.(+3)OOH) in the battery
discharged state.
10. The alkali/oxidant battery of claim 1 wherein the cathode
includes (Fe.sup.(3+)(OH).sub.3) in the battery charged state and
iron(II) oxyhydroxide (Fe.sup.(2+)(OH).sub.2) in the battery
discharged state.
11. The alkali/oxidant battery of claim 1 wherein the cathode in
the battery charged state is NiOOH, and progresses from the battery
charged state to the battery discharged state with the following
reaction: NiOOH+H.sub.2O+e.sup.-=Ni(OH).sub.2+OH--.
12. The alkali/oxidant battery of claim 1 wherein the cathode in
the battery charged state is Mn.sup.(4+)O.sub.2, and progresses
from the battery charged state to the battery discharged state with
the following reaction:
Mn.sup.(4+)O.sub.2+H.sub.2O+e.sup.-.fwdarw.Mn.sup.(3+)OOH+OH--.
13. The alkali/oxidant battery of claim 1 wherein the cathode in
the battery charged state is Fe.sup.(3+)(OH).sub.3, and progresses
from the battery charged state to the battery discharged state with
the following reaction:
Fe.sup.(3+)(OH).sub.3+e.sup.-.fwdarw.Fe.sup.(2+)(OH).sub.2+OH--.
14. The alkali/oxidant battery of claim 1 wherein the anode in the
battery charged state is selected from a group consisting of a
solid phase reduced first alkali metal and a solid phase reduced
first alkali metal overlying a current collector.
15. A method for creating alkali/oxidant battery capacity, the
method comprising: forming a battery in a charged state having a
first alkali metal anode, an anolyte, a first alkali metal ion
permeable separator, and a cathode including an oxidized element
selected from a group consisting of nickel oxyhydroxide (NiOOH),
magnesium(IV) oxide (Mn.sup.(4+)O.sub.2), and iron(III)
oxyhydroxide (Fe.sup.(3+)(OH).sub.3), and a catholyte including a
first alkali metal hydroxide; creating a first battery capacity,
where the first battery capacity is responsive to an amount of
oxidized element in the cathode and reduced first alkali metal at
the anode.
16. The method of claim 15 wherein forming the battery includes
forming, in the charged battery state, a NiOOH cathode, and a
reduced first alkali metal (X) anode, where X is selected from a
group consisting of lithium (Li), sodium (Na), and potassium (K);
and, the method further comprising: discharging the battery by
performing the following reactions: anode: X.dbd.X.sup.++e.sup.-
and, cathode: NiOOH+H.sub.2O+e.sup.-=Ni(OH).sub.2+OH--.
17. The method of claim 15 wherein forming the battery includes
forming, in the charged state, a Mn.sup.(4+)O.sub.2 cathode, and a
reduced first alkali metal (X) anode, where X is selected from a
group consisting of Li, Na, and K; and, the method further
comprising: discharging the battery by performing the following
reactions: anode: X.dbd.X.sup.++e.sup.- and, cathode:
Mn.sup.(4+)O.sub.2+H.sub.2O+e.sup.-.fwdarw.Mn.sup.(3+)OOH+OH--.
18. The method of claim 15 wherein forming the battery includes
forming, in the charged state, a Fe.sup.(3+)(OH).sub.3 cathode, and
a reduced first alkali metal (X) anode, where X is selected from a
group consisting of Li, Na, and K; and, the method further
comprising: discharging the battery by performing the following
reactions: anode: X.dbd.X.sup.++e.sup.- and, cathode:
Fe.sup.(3+)(OH).sub.3+e.sup.-.fwdarw.Fe.sup.(2+)(OH).sub.2+OH--.
19. The method of claim 15 further comprising: discharging the
battery by forming the anolyte including ions selected from a group
of first alkali metals consisting of lithium ions (Li.sup.+),
sodium ions (Na.sup.+), and potassium ion (K.sup.+) dissolved in
the anolyte.
20. The method of claim 15 wherein forming the battery includes the
cathode and catholyte being a cathode slurry.
21. A lithium (Li)/nickel (Ni) battery comprising: an anode
including reduced Li in a battery charged state; an anolyte; a
cathode including Ni oxyhydroxide (Ni(OH).sub.2) in the battery
discharged state and nickel oxyhydroxide (NiOOH) in a battery
charged state; a catholyte including LiOH; and, a lithium ion
(Li.sup.+) permeable separator interposed between the anolyte and
the catholyte.
Description
RELATED APPLICATION
[0001] The application is a Continuation-in-Part of a pending
application entitled, FLOW-THROUGH METAL BATTERY WITH ION EXCHANGE
MEMBRANE, invented by Yuhao Lu et al., Ser. No. 14/042,264, filed
on Sep. 30, 2013, Attorney Docket No. SLA3294;
[0002] which is a Continuation-in-Part of a pending application
entitled, BATTERY WITH LOW TEMPERATURE MOLTEN SALT (LTMS) CATHODE,
invented by Yuhao Lu et al., Ser. No. 13/564,015, filed on Aug. 1,
2012, Attorney Docket No. SLA3165. Both these applications are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention generally relates to electrochemical cells
and, more particularly, to a battery formed from an alkali anode
and cathode including nickel, magnesium, or iron.
[0005] 2. Description of the Related Art
[0006] A battery is an electrochemical device in which electrons
and ions commute between the anode and cathode to realize
electrochemical reactions. The voltage and capacity of the battery
are determined by the electrode materials. In a conventional
battery, all the components including anode materials, cathode
materials, separator, electrolyte, and current collectors are
packed into a volume-fixed container. Its energy and capacity of
are unchangeable as long as the battery is assembled. A
flow-through battery consists of current collectors (electrodes)
separated by an ion exchange membrane, while its anode and cathode
materials are stored in separate storage tanks. The anode and
cathode materials are circulated through the flow-through battery
in which electrochemical reactions take place to deliver and to
store energy. Therefore, the battery capacity and energy are
determined by (1) electrode materials (anolyte and catholyte), (2)
the concentrations of anolyte and catholyte, and (3) the volumes of
anolyte and catholyte storage tanks. Conventional state-of-the-art
anode and cathode materials typically react with an aqueous or
non-aqueous solution (electrolyte) containing some redox
couples.
[0007] In general, the use of metals as anode materials can achieve
a high voltage in the battery while their low molecular weight
provides a large capacity. For example, lithium has the most
negative potential of 3.04 volts (V) vs. H.sub.2/H.sup.+ and the
highest capacity of 3860 milliamp hours per gram (mAh/g). High
voltage and large capacity lead to an overall high energy for the
battery. In addition, sodium, potassium, magnesium, nickel, zinc,
calcium, aluminum, etc. are good candidates as the anode materials
in metal-ion batteries.
[0008] The state-of-the-art cathode materials focus on the
metal-ion host compounds. Metal-ions can be extracted from the
interstitial spaces of the electrode materials in the charge
process and inserted into the materials during the discharge
process. However, it is worth noting that the charge/discharge
process severely distorts the lattice of the materials, which
essentially destroys their structures following several cycles.
Moreover, these cathode materials can only provide less than one
tenth capacities of the metal anode materials. Therefore, new
cathode materials need to be developed in order to (1) match the
higher capacities of the anode materials and (2) exhibit long cycle
lives for the metal-ion batteries.
[0009] In 1996, Abraham and Jiang reported a polymer
electrolyte-based rechargeable lithium/oxygen battery in which
oxygen was used as the cathode material.sup.1. Oxygen in air
continuously flowed into the battery and provided a very high
specific energy of 5200 watt hours per kilogram (Wh/kg).
Nevertheless, the oxygen cathode has several disadvantages.
Firstly, expensive electro-catalysts were used in the batteries to
reduce the kinetic barrier for the oxygen reactions. Secondly, the
sluggish electrochemical reactions of oxygen produce a large
overpotential in the lithium/air battery. Thirdly, the lithium/air
battery must maintain an open cathode to allow air access.
Similarly, an oxygen cathode was also used in the zinc-air
batteries.
[0010] In 2011, Lu and Goodenough revealed an aqueous cathode for a
lithium-ion battery.sup.3. They used aqueous solutions of
water-soluble redox couples, for example,
Fe(CN).sub.3.sup.3-/Fe(CN).sub.6.sup.4- as the cathode. The
lithium/aqueous cathode battery operated at ca. 3.4 volts in an
ambient environment. The battery demonstrated a small
overpotential, a high coulombic efficiency, and a long cycle life.
However, water is an inert material in the electrochemical system,
which reduces the specific capacity of the cathode. Although the
design of a lithium/flow-through cathode battery can increase the
capacity and energy, its volume must necessarily be large.
[0011] With the similar battery structure, Ni(OH).sub.2 was used as
the cathode to match a lithium anode.sup.4. The Li/Ni(OH).sub.2
battery has to be charged so that Ni(OH).sub.2 can be oxidized to
NiOOH along the reaction:
Ni(OH).sub.2+OH--=NiOOH+H.sub.2O+e.sup.-.
[0012] At the same time, the following reaction occurs:
Li.sup.++e.sup.-=Li
[0013] in which lithium-ions come are sourced from the electrolyte.
Therefore, the battery capacity is limited by the Li-ion
concentration in electrolytes, although Ni(OH).sub.2 experimentally
demonstrate a high capacity of 260 mAh/g. The capacity advantage of
the Li/Ni battery is limited by the Li-ion concentration in the
electrolyte.
[0014] It would be advantageous if NiOOH could be used as the
cathode material in a battery with a lithium anode, so that the
capacity of a Li/Ni battery is determined by the amount of NiOOH in
the cathode at fabrication. [0015] [1] K. M. Abraham, Z. Jiang, "A
polymer electrolyte-based rechargeable lithium/oxygen battery",
Journal of the Electrochemical Society, 143 (1996) 1-5. [0016] [2]
Philip N. Ross, Jr., "Zinc electrode and rechargeable zinc-air
battery", U.S. Pat. No. 4,842,963. [0017] [3] Yuhao Lu, john B.
Goodenough, Youngsik Kim, "Aqueous cathode for next generation
alkali-ion batteries". Journal of the American Chemical Society,
133 (2011), 5756-5759. [0018] [4] H. Li, Y. Wang, H. Na, H. Liu, H.
Zhou, "Rechargeable Ni--Li battery integrated aqueous/nonaqueous
system", J. Am. Chem. Soc, 131 (2009) 15098-15099. [0019] [5]
William C. Carter, Yet-Ming Chiang, "High energy density redox flow
device" US 2011/0189520.
SUMMARY OF THE INVENTION
[0020] Disclosed herein is a lithium anode battery that uses nickel
oxyhydroxide (NiOOH), magnesium(IV) (oxide Mn.sup.(4+)O.sub.2), or
iron(III) oxyhydroxide (Fe.sup.(3+)(OH).sub.3) as the cathode
material in an alkali metal anode battery. The cathode material may
he fixed as a solid on a current collector and also can be made as
a slurry catholyte, which flows through cathode side of the
battery, permitting the battery to be rapidly charged using a
mechanical (as opposed to an electrical/chemical) method.
[0021] Accordingly, an alkali/oxidant battery is provided. The
battery is made from an anode including a reduced first alkali
metal lithium (Li), sodium (Na), and potassium (K), when the
battery is charged. The battery's cathode includes an element, in
the battery charged state, such as NiOOH, Mn.sup.(4+)O.sub.2, or
Fe.sup.(3+)(OH).sub.3, with an alkali metal hydroxide in the
catholyte. An alkali metal ion permeable separator is interposed
between the anolyte and the catholyte. For example, if the cathode
includes nickel(II) hydroxide (Ni(OH).sub.2) in a battery
discharged state, then it includes NiOOH in a battery charged
state. To continue the example, the anolyte may include dissolved
lithium ions (Li.sup.+) in a discharged state, with solid phase
reduced Li formed on the anode in the battery charged state.
[0022] In one aspect, the cathode and catholyte are the same
element, formed a cathode slurry, with a cathode current collector
submerged in the cathode slurry. In this aspect, a cell includes
the anode, anolyte, and separator, and a cathode slurry reservoir
connected to the cell input and output ports to supply an oxidized
cathode slurry when the battery is electrically charged, or
discharging under load, and a reduced cathode slurry when the
battery is being electrically charged. Further, a plurality of
cells may be connected in series or parallel electrical
connections.
[0023] Additional details of the above-described battery and a
method for creating alkali/oxidant battery capacity are provided
below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a partial cross-sectional view of a charged
alkali/oxidant battery.
[0025] FIG. 2 is a partial cross-sectional view of the
alkali/oxidant battery in the discharged state.
[0026] FIGS. 3A and 3B are partial cross-sectional views depicting
an alkali/oxidant battery where the anode is a material dissolved
in the anolyte.
[0027] FIGS. 4A and 4B are partial cross-sectional views of an
alkali/oxidant battery where the catholyte and cathode are the same
element, comprising a cathode slurry.
[0028] FIGS. 5 and 6 are partial cross-sectional views of an
alternative alkali/oxidant battery using a cathode slurry.
[0029] FIG. 7 is a schematic block diagram depicting a plurality of
cells.
[0030] FIG. 8 is a partial cross-sectional schematic block diagram
depicting the alkali/oxidant battery from a different
perspective.
[0031] FIG. 9 is a partial cross-section schematic block diagram
depicting a flowthrough battery with a cathode slurry.
[0032] FIG. 10 is a partial cross-sectional schematic block diagram
of several blocks of batteries connected by pipelines to a slurry
reservoir.
[0033] FIG. 11 is a flowchart illustrating a method for creating
alkali/oxidant battery capacity.
DETAILED DESCRIPTION
[0034] FIG. 1 is a partial cross-sectional view of a charged
alkali/oxidant battery. The battery 100 comprises an anode 102
including a reduced first alkali metal 104, in the battery charged
state, and an anolyte 106. The battery 100 further comprises a
cathode 110 including, in the battery charged state, an oxidized
material 113 such as nickel oxyhydroxide (NiOOH), magnesium(IV)
oxide (Mn.sup.(4+)O.sub.2), or iron(III) oxyhydroxide
(Fe.sup.(3+)(OH).sub.3), and a catholyte 111 including a first
alkali metal hydroxide 108. Here, the first alkali metal hydroxide
is schematically represented as an oval element within the
catholyte 111, for the sake of simplicity. These cathode materials
are insoluble in water, to promote stable cycling. They have a
well-defined potential associated with the redox couple, and a low
molecular weight to promote a high energy density The catholyte may
be aqueous because at the potential at which the redox occurs,
water suffices, as it does not react or breakdown. Further, water
is cheap and non-flammable, unlike organic electrolytes. A first
alkali metal ion permeable separator 112 is interposed between the
anolyte 106 and the catholyte 111. The anolyte typically includes
an organic solvent, such as ethylene carbonate, diethyelene
carbonate, or a mixture of the two. For example, a lithium salt,
such as LiPF.sub.6, when dissolved in a solvent, dissociates into
Li.sup.+PF.sub.6.sub.-.
[0035] The separator 112 is a permeable membrane placed between the
anode 102 and cathode 110 to keep the two electrodes apart,
preventing electrical short circuits, while allowing the transport
of ionic charge carriers that are needed to close the circuit
during the passage of current in the battery 100. The separator 112
may be a polymeric membrane forming a microporous layer. It is
typically chemically and electrochemically stable with regard to
the anolyte and catholyte materials.
[0036] FIG. 2 is a partial cross-sectional view of the
alkali/oxidant battery in the discharged state. As used herein, a
battery is in a charged state when electrochemically active
materials in the cathode are in an oxidized state and
electrochemical materials in anode are in a reduced state. When a
battery is in a discharged state, electrochemically active
materials in the cathode are in a reduced state and electrochemical
materials in the anode are in an oxidized state. Alternatively
stated, a battery is charged when, upon providing an external
connection through a load between the cathode and anode,
spontaneous electrochemical reactions occur such that current flows
from cathode to anode (or electrons from anode to cathode).
Occurring simultaneously, these reactions reduce cathode active
material and oxidize anode active material. Likewise, a battery is
discharged when, upon providing an external connection through a
load between the cathode and anode, no spontaneous electrochemical
reactions occur and that no current flows from cathode to anode (or
electrons from anode to cathode). Instead, an external source of
power is required to force current to flow from anode to cathode
(or electrons from cathode to anode) to reverse the otherwise
spontaneous reactions in a charged battery.
[0037] Generally, the battery 100 operates as a result of redox
reactions involving oxidation, which is the loss of electrons or an
increase in oxidation state by a molecule, atom, or ion, and
reduction, which is the gain of electrons or a decrease in
oxidation state by a molecule, atom, or ion. In one case,
referencing both FIGS. 1 and 2, the cathode 110 includes a reduced
element 200, such as nickel(II) hydroxide (Ni(OH).sub.2) in the
battery discharged state and an oxidized element 113, such as
NiOOH, in the battery charged state. To continue the example, the
anolyte 106 may include alkali metal ions 202, such as lithium ions
(Li.sup.+), in the battery discharged state. More generally, the
anolyte 106 in the battery discharged state includes alkali metals
ion 202 such as lithium ions (Li.sup.+), sodium ions (Na.sup.+), or
potassium ions (K.sup.+). In the battery charged state, the anode
102 includes a solid phase reduced alkali metal 104, respectively,
Li, Na, or K.
[0038] In other examples, the cathode 110 includes magnesium(IV)
oxide (Mn.sup.(4+)O.sub.2) 113 in the battery charged state and
magnesium (III) oxyhydroxide (Mn.sup.(3+)OOH) 200 in the battery
discharged state. Alternatively, the cathode 110 includes
Fe.sup.(3+)(OH).sub.3 113 in the battery charged state and iron(II)
oxyhydroxide (Fe.sup.(2+)(OH).sub.2) 200 in the battery discharged
state.
[0039] When the cathode 110 in the battery charged state is NiOOH,
it progresses from the battery charged state to the battery
discharged state with the following reaction:
NiOOH+H.sub.2O+e.sup.-=Ni(OH).sub.2+OH--.
[0040] When the cathode 110 in the battery charged state is
Mn.sup.(4+)O.sub.2, it progresses from the battery charged state to
the battery discharged state with the following reaction:
Mn.sup.(4+)O.sub.2+H.sub.2O+e.sup.-.fwdarw.Mn.sup.(3+)OOH+OH--.
[0041] When the cathode 110 in the battery charged state is
Fe.sup.(3+)(OH).sub.3, it progresses from the battery charged state
to the battery discharged state with the following reaction:
Fe.sup.(3+)(OH).sub.3+e.sup.-.fwdarw.Fe.sup.(2+)(OH).sub.2+OH--.
[0042] FIGS. 1 and 2 depict the alkali/oxidant battery with an
active material solid phase anode and active material cathode. By
"active material" it is meant that anode 102 and cathode 110 react,
respectively, with the anolyte 106 and catholyte 111 in the redox
reactions that enable the battery to charge and discharge. Although
not explicitly shown, the anode 102 and cathode 110 may be formed
overlying a current collector.
[0043] In this example, the anode 102 is a reduced solid phase
alkali metal 104 such as Li, Na, or K when the battery is in the
charged state. Further, the cathode 110 includes Mn.sup.(4+)O.sub.2
113 in the battery charged state and Mn.sup.(+3)OOH 200 in the
battery discharged state. Alternatively, the cathode 110 includes
Fe.sup.(3+)(OH).sub.3 113 in the battery charged state and
Fe.sup.(2+)(OH).sub.2 200 in the battery discharged state. In
another aspect, the cathode 110 in the battery charged state is
NiOOH 113, and in the battery discharged state it is Ni(OH).sub.2
200. For example, Ni(OH).sub.2 powder may be mixed with a binder (a
polymer) and a conductive carbon (carbon black or graphite or
carbon fiber) in water to form a paste that is applied to current
collector (nickel foil or nickel foam). The cathode is pressed and
heated to dry out water. The cathode 110 is referred to herein as
"solid", but it has microscopic pores into which catholyte 111
penetrate via capillary force.
[0044] FIGS. 3A and 3B are partial cross-sectional views depicting
an alkali/oxidant battery where the anode is a material dissolved
in the anolyte. The cathode 110 and catholyte 111 are as described
above in the explanation of FIGS. 1 and 2, except a cathode current
collector 300 is explicitly shown. In this aspect, the anode in the
battery charged state (FIG. 3A) comprises reduced alkali metal 104
(i.e. Li, Na, or K) formed on current collector 302. In the battery
discharged state, alkali metal ions 202 (i.e. Li+, Na+, or K+) are
dissolved in the anolyte 106. In the battery discharged state, no
alkali metal necessarily adheres on the current collector 302.
[0045] FIGS. 4A and 4B are partial cross-sectional views of an
alkali/oxidant battery where the catholyte and cathode are the same
element, comprising a cathode slurry. A cathode current collector
300 is submerged in the cathode slurry 110/111. In these figures,
the anode 102 and anolyte 106 are the same as described above in
the explanation of FIGS. 1 and 2, and the explanations are not
repeated in the interest of brevity. A cell 400 comprises the anode
102, the anolyte 106, the first alkali metal ion permeable
separator 112, an input port 402 and an output port 404. A cathode
slurry reservoir 406 is connected to the cell input 402 and output
404 ports to supply an oxidized cathode slurry 113 in the battery
charged state (FIG. 4A), or to maintain a charge under an
electrical load, and a reduced cathode slurry 200 when the battery
is in the discharge state (FIG. 4B), or when it being electrically
charged. For the sake of simplicity, the oxidized cathode slurry
113 and reduced cathode slurry 200 are schematically represented as
ovals within the cathode slurry 110/111.
[0046] FIGS. 5 and 6 are partial cross-sectional views of an
alternative alkali/oxidant battery using a cathode slurry. In these
figures, the anode 102 and anolyte 106 are the same as described
above in the explanation of FIGS. 3A and 3B, and the explanations
are not repeated in the interest of brevity. A cell 400 comprises
the anode 102, the anolyte 106, the first alkali metal ion
permeable separator 112, an input port 402 and an output port 404.
A cathode slurry reservoir 406 is connected to the cell input 402
and output 404 ports to supply an oxidized cathode slurry 113 in
the battery charged state (FIG. 5), to maintain a charge under an
electrical load, and a reduced cathode slurry 200 when the battery
is in the discharge state (FIG. 6), or when it is being
electrically charged.
[0047] FIG. 7 is a schematic block diagram depicting a plurality of
cells. Shown are cells 700-0 through 700-n, where n is an integer
greater than one, but not otherwise limited to any particular
value. The cells 700-0 through 700-n are shown electrically
connected in series, but alternatively (not shown), they may be
electrically connected in parallel. In one aspect, as shown, the
cathode slurry reservoir 406 and the plurality of cells 700-0
through 700-n are connected in parallel to transport the cathode
slurry 110/111. Alternatively but not shown, the cells may be
connected in series with the slurry reservoir.
[0048] FIG. 8 is a partial cross-sectional schematic block diagram
depicting the alkali/oxidant battery from a different perspective.
In one aspect as shown, NiOOH is used as the cathode material 802
in a lithium/nickel battery 800. The battery 800 comprises a
lithium metal anode 84 and a NiOOH cathode 8 separated by a Li-ion
permeable separator 806 that conveys Li-ions 808 between anode 804
and cathode 802 sides. The lithium/NiOOH battery 800 has to be
discharged after initial assembly, with the electrochemical
reactions:
anode side: Li.dbd.Li+e.sup.-;
cathode side: NiOOH+H.sub.2O+e.sup.-=Ni(OH))+OH--.
overall reaction: Li+NiOOH+H.sub.2O.dbd.Ni(OH).sub.2+LiOH.
[0049] Unlike the lithium/Ni(OH).sub.2 battery associated with
reference 4 (H. Li et al.), and described in the Background Section
above, whose capacity is limited by the Li-ion concentration in
electrolyte, the capacity of Li/NiOOH battery of FIG. 8 is only
determined by the active materials in the electrodes. Specifically,
for reference 4, the anode is Li, cathode is Ni(OH).sub.2, and the
electrolyte has LiOH. The first reaction after battery assembly
must be the process of charging the battery. During the charge
process, the LiOH in the electrolyte is dissociated, Li.sup.+ moves
to the anode side and becomes plated on the Li metal anode, OH--
ions react with Ni(OH).sub.2, resulting in NiOOH and H.sub.2O. The
capacity of the battery is determined by the amount of LiOH added
to the liquid electrolyte.
[0050] In battery 800, the anode is Li metal and the cathode is
NiOOH. Unlike the above-mentioned prior art battery (reference 4),
the first reaction after battery assembly is to discharge battery
800. The Li+ dissolves into anolyte at the anode side and moves to
cathode side. The cathode material NiOOH reacts and results in
Ni(OH).sub.2. The battery capacity is limited by the original
amount of Li or NiOOH present when the battery is fabricated. Since
the Li has very large capacity (>3000 mAh/g), greater than the
LiOOH cathode (261 mAh/g), the Li/NiOOH battery capacity is
determined by the original amount of NiOOH at the cathode.
Therefore, the initially charged battery with NiOOH cathode has a
much higher capacity than that one in reference 4, that is
initially discharged with a Ni(OH).sub.2 electrode and a LiOH
liquid electrolyte.
[0051] FIG. 9 is a partial cross-section schematic block diagram
depicting a flowthrough battery with a cathode slurry. Once the
NiOOH of battery 800 is attached onto a current collector at
assembly, the battery capacity is fixed. In order to increase the
battery capacity further, the flowthrough battery 900 of FIG. 9
forms NiOOH as a slurry catholyte 902 that can be fed into the
cathode current collector 904 to match the high capacity of lithium
anode 804. Carter and Chiang (reference 5, see Background Section),
disclosed the use of a flowable slurry as the electrode materials
in batteries. However, their battery with a LiCoO.sub.2 slurry
catholyte demonstrated 0.36 Li-ion reversibly inserting/extracting
into/from a LiCoO.sub.2 molecule between 2 V and 4.5 V,
corresponding to a capacity of 99 mAh/g, much smaller than that of
NiOOH, which is 261 mAh/g. The flowthrough Li/NiOOH battery 900
consists of lithium anode 804, and a cathode compartment separator
of a Li-ion permeable membrane or a Li-ion conducting solid
electrolyte 806. During the discharge, NiOOH is reduced to
Ni(OH).sub.2. If mechanically charged (the cathode slurry is
refreshed with oxidized slurry from a reservoir), the battery 900
can continue to generate electric powder. Similarly, the anode
compartment can be also easily disassembled for the anode to be
replaced, realizing a mechanical charge. In some aspects, the
current collector 904 may additionally be comprised of the wall of
the compartment containing the slurry.
[0052] FIG. 10 is a partial cross-sectional schematic block diagram
of several blocks of batteries connected by pipelines to a slurry
reservoir. Each block 1002 includes a plurality of flowthrough
batteries 900 electrically connected in parallel. In order to
obtain high voltage and high energy, the blocks 1002 can be
electrically connected in series, as shown, to form battery stack
1000. Several blocks 1002 can be connected by the pipe lines in
parallel (as shown) or series to circulate NiOOH slurry catholyte.
Like the flowthrough Li/NiOOH battery of FIG. 9, the stack 1000 can
also be mechanically charged with Li-anode replacement and NiOOH
slurry catholyte replenishment.
[0053] Below is a summary of the battery configurations described
in FIGS. 1 through 6:
[0054] 1. Slurry cathode/solid, metallic anode
[0055] 2. Solid cathode/solid, metallic anode
[0056] 3. Slurry cathode/anode material dissolved in anolyte
[0057] 4. Solid cathode/anode material dissolved in anolyte
[0058] There is no phase change for slurry or solid cathodes as
they progress from reduced to oxidized state (and from oxidized to
reduced states). For a battery to either discharge or charge (i.e.
redox reactions occur together at the anode and cathode), the
oxidation states of cathode and anode must be opposite.
TABLE-US-00001 TABLE 1 Battery with Ni slurry cathode/solid,
metallic Li anode (1) Cathode side Anode side Process Before After
Before After Discharging NiOOH Ni(OH).sub.2 Li Li.sup.+ (oxidized)
(reduced) (reduced-a (oxidized- solid) dissolved in electrolyte)
Charging Ni(OH).sub.2 NiOOH Li.sup.+ Li (reduced) (oxidized)
(oxidized- (reduced-a dissolved in solid) electrolyte)
[0059] During discharge, slurry cathode enters in an oxidized state
(NiOOH) and the anode is metallic Li (in reduced state). Slurry
leaves in a reduced state (Ni(OH).sub.2. Subsequently, the battery
can be charged by reversing the flow of slurry, i.e., Ni(OH).sub.2
enters in reduced state and leaves in oxidized state (NiOOH),
Metallic Li dissolves when it is oxidized., i.e., Li.sup.+ is
soluble in an aqueous electrolyte. The battery has a high capacity,
determined by the amount of solid metal anode (as opposed to
concentration of alkali metal ion in electrolyte solution, which
would be much smaller).
TABLE-US-00002 TABLE 2 Battery with Ni slurry cathode/anode
material dissolved in anolyte (3). Cathode side Anode side Process
Before After Before After Charging Ni(OH).sub.2 NiOOH Li.sup.+ Li
(reduced) (oxidized) (oxidized- (reduced- dissolved a solid) in
electrolyte) Discharging NiOOH Ni(OH).sub.2 Li Li.sup.+ (oxidized)
(reduced) (reduced- (oxidized- a solid) dissolved in
electrolyte)
[0060] As previously mentioned, metallic Li dissolves when it is
reduced, i.e., Li.sup.+ is soluble in an aqueous electrolyte. So it
is possible to build a battery with no solid anode, just a current
collector of suitable material. The metal ions (oxidized) are
dissolved in anolyte solution, During charge, slurry cathode enters
in a reduced state (Ni(OH).sub.2) as the anode is oxidized. Slurry
leaves in oxidized state (NiOOH). Subsequently, the battery can be
discharged by reversing the flow of slurry, i.e., NiOOH enters in
oxidized state and leaves in reduced state (Ni(OH)2), Metallic Li
plates on the current collector when it is reduced. The battery
capacity is determined by concentration of metal ions in the
electrolyte solution.
[0061] FIG. 11 is a flowchart illustrating a method for creating
alkali/oxidant battery capacity. Although the method is depicted as
a sequence of numbered steps for clarity, the numbering does not
necessarily dictate the order of the steps. It should be understood
that some of these steps may be skipped, performed in parallel, or
performed without the requirement of maintaining a strict order of
sequence. Generally however, the method follows the numeric order
of the depicted steps. The method starts at Step 1100.
[0062] Step 1102 forms a battery in a charged state having a first
alkali metal anode, an anolyte, a first alkali metal ion permeable
separator, and a cathode including an oxidized element. The
oxidized element may be nickel oxyhydroxide (NiOOH), magnesium(IV)
oxide (Mn.sup.(4+)O.sub.2), or iron(III) oxyhydroxide
(Fe.sup.(3+)(OH).sub.3). The battery further comprises a catholyte
including a first alkali metal hydroxide. In one aspect, the
cathode and catholyte are a cathode slurry. Step 1104 creates a
first battery capacity, where the first battery capacity is
responsive to the amount of oxidized element in the cathode and
reduced first alkali metal at the anode.
[0063] In one aspect, Step 1102 forms a battery, in the charged
state, with a NiOOH cathode, and a reduced first alkali metal (X)
anode, where X is lithium (Li), sodium (Na), or potassium (K).
Then, Step 1006 discharges the battery by performing the following
reactions:
anode: X.dbd.X.sup.++e.sup.- and,
cathode: NiOOH+H.sub.2O+e.sup.-=Ni(OH).sub.2+OH--.
[0064] In another aspect, Step 1102 forms a battery, in the charged
state, with a Mn.sup.(4+)O.sub.2 cathode, and a reduced first
alkali metal (X) anode, where X is Li, Na, or K. Then, discharging
the battery in Step 1106 includes performing the following
reactions:
anode: X.dbd.X.sup.++e.sup.- and,
cathode:
Mn.sup.(4+)O.sub.2+H.sub.2O+e.sup.-.fwdarw.Mn.sup.(3+)OOH+OH--.
[0065] In yet another aspect, Step 1102 forms a battery, in the
charged state, with a Fe.sup.(3+)(OH).sub.3 cathode, and a reduced
first alkali metal (X) anode, where X is Li, Na, or K. Then,
discharging the battery in Step 1106 includes performing the
following reactions:
anode: X.dbd.X.sup.++e.sup.- and,
cathode:
Fe.sup.(3+)(OH).sub.3+e.sup.-.fwdarw.Fe.sup.(2+)(OH).sub.2+OH---
.
[0066] In one aspect, discharging the battery in Step 1106 includes
forming the anolyte with lithium ions (Li.sup.+), sodium ions
(Na.sup.+), or potassium ion (K.sup.+) dissolved in the
anolyte.
[0067] An alkali/oxidant battery has been provided along with an
associated method for creating a battery capacity. Examples of
materials and slurry flow configurations have been presented 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.
* * * * *