Modified polyphenylene sulfide (PPS) and PPS modification method, PPS solid separator, prefabricated zinc salt separator and manufacturing method thereof, to-be-filled zinc-manganese secondary battery, and manufacturing and application methods thereof

Patent metadata

Field	Value
Publication number	US-12444807-B2
Application number	US-202418860698-A
Country	US
Kind code	B2
Filing date	Apr 8, 2024
Priority date	Apr 13, 2023
Publication date	Oct 14, 2025
Grant date	Oct 14, 2025

Abstract

Modified polyphenylene sulfide (PPS) and a PPS modification method, a PPS solid separator, a prefabricated zinc salt separator and a manufacturing method thereof, a to-be-filled zinc-manganese secondary battery and a manufacturing method, a formation method and an application method thereof are provided. Through hydrothermal synthesis, tetrachlorobenzoquinone in PPS powder undergoes a dechlorination and hydrogenation reaction to form molecules with a chlorocatechol structure, to improve the adsorption performance of the PPS solid separator towards harmful molecules. Moreover, in combination with the protection of welding spots during the battery assembly process, and a formation method involving injection of an aqueous electrolyte solution followed by alcohol during the formation process, the cycling stability of the battery is improved and the service temperature range of the battery is broadened.

First claim

What is claimed is:

1. A manufacturing method of a to-be-filled zinc-manganese secondary battery, wherein the to-be-filled zinc-manganese secondary battery is manufactured with a prefabricated zinc salt separator, wherein a manufacturing method of the prefabricated zinc salt separator, comprises:
(1) providing one of a polyphenylene sulfide (PPS) solid separator (A) and an upper support separator (B) with a glue liquid (C) by dipping or coating, and bonding the PPS solid separator (A) and the upper support separator (B) together with the glue liquid (C) being located between the PPS solid separator (A) and the upper support separator (B); laminating the upper support separator (B) with the PPS solid separator (A) through roll-pressing; and drying the upper support separator (B) and the PPS solid separator (A) that are laminated, to obtain a double-layer prefabricated zinc salt separator (D); and
(2) providing one of an exposed surface of the PPS solid separator (A) of the double-layer prefabricated zinc salt separator (D) and a lower support separator (F) with a glue liquid (E) by dipping or coating, and bonding the exposed surface of the PPS solid separator (A) of the double-layer prefabricated zinc salt separator (D) and the lower support separator (F) together with the glue liquid (E) being located between the exposed surface of the PPS solid separator (A) of the double-layer prefabricated zinc salt separator (D) and the lower support separator (F); laminating the lower support separator (F) with the double-layer prefabricated zinc salt separator (D) to obtain a three-layer separator; and drying the three-layer separator to obtain a prefabricated zinc salt separator (H),
wherein the upper support separator (B) and the lower support separator (F) are both porous separators, and the glue liquid (C) and the glue liquid (E) are each a mixture of an organic adhesive and/or an inorganic adhesive, an electrolyte zinc salt, and a solvent,
wherein the prefabricated zinc salt separator comprises the PPS solid separator (A), and the upper support separator (B) and the lower support separator (F) located on both sides of the PPS solid separator (A), wherein a mixture comprising the organic adhesive and/or the inorganic adhesive and the electrolyte zinc salt is filled between the upper support separator (B) and the PPS solid separator (A) and between the lower support separator (F) and the PPS solid separator (A),
wherein the prefabricated zinc salt separator (H) is arranged between a manganese oxide positive electrode and a zinc negative electrode, electrode tabs are welded, a battery cell is prepared by a stacking machine or a winding machine, the battery cell is placed into a battery case or an aluminum-plastic film pouch, and the battery case or the aluminum-plastic film pouch is sealed and stored for later use, wherein the battery case or the aluminum-plastic film pouch is provided with a sealable liquid injection port,
wherein a manufacturing method of the manganese oxide positive electrode comprises: mixing manganese dioxide with polytetrafluoroethylene (PTFE) first;
using a dry supersonic jet gas to allow molecular chains of the PTFE to open and physically adhere to a positive electrode material powder below a glass transition temperature of the PTFE;
spraying an alcohol solution onto fiberized powder;
performing internal mixing and shearing granulation followed by hot-rolling to form a positive electrode film;
laminating multiple layers of the positive electrode film through multiple cold rolling to form a composite positive electrode self-supporting film with a thickness of 100 μm to 150 μm;
and laminating the composite positive electrode self-supporting film with a glue-coated sandblasted stainless steel foil through a hot roller press.

2. The manufacturing method of the to-be-filled zinc-manganese secondary battery according to claim 1 , wherein a manufacturing method of the zinc negative electrode comprises:
mixing zinc powder, a conductive agent, a toughening conductive agent, a cationic retarder, and a hydrogen evolution inhibitor uniformly in a mixer to obtain powder (A), wherein the cationic retarder is inorganic powder that is electronegative and swells with water, the hydrogen evolution inhibitor is a metal compound that undergoes a reduction reaction with the zinc powder in an alcohol-water solvent, and a weight ratio of the zinc powder, the conductive agent, the toughening conductive agent, the cationic retarder, PTFE, and the hydrogen evolution inhibitor is (60% to 90%):(1% to 10%):(1% to 10%):(1% to 10%):(3% to 15%):(0.1% to 5%);
mixing PTFE powder and the powder (A) uniformly in the mixer under a temperature condition such that the PTFE is in a glassy state, to obtain powder (B);
mixing the powder (B) and an alcohol-water mixed solvent in a ball mill, wherein the PTFE is continuously rubbed by ball mill beads rotating at a high speed to form a network structure of PTFE filaments, molecular chains of the PTFE in the powder (B) are extended and opened, and physically adhered to powder in the powder (A), the hydrogen evolution inhibitor undergoes the reduction reaction with a surface of the zinc powder, and after above processes are completed, filtration is conducted to obtain a gel mass (C);
subjecting the gel mass (C) to internal mixing to form a uniform gel mass, and shear-granulating the uniform gel mass to produce millimeter-sized granules (E) of a uniform size;
hot-pressing the millimeter-sized granules (E) through a horizontal hot roller press to form a negative electrode film (F), winding the negative electrode film (F) with a porous release paper as a support tape, and drying the negative electrode film (F) attached with the porous release paper as a whole to remove part of the alcohol-water mixed solvent; and
with a hot-press lamination process, thermally laminating a semi-dry negative electrode film (F) with the porous release paper removed onto both sides of a glue-coated stainless steel foil, to form the zinc negative electrode.

3. The manufacturing method of the to-be-filled zinc-manganese secondary battery according to claim 2 , wherein the zinc powder is powdery particles with a particle size of 5 μm to 20 μm; the conductive agent is one or both of super-P and electrically conductive carbon black (ECP); and the toughening conductive agent is one of, or a mixture of artificial graphite and high-purity graphite.

4. The manufacturing method of the to-be-filled zinc-manganese secondary battery according to claim 2 , wherein the cationic retarder is one or more of bentonite, montmorillonite powder, illite powder, kaolin powder, and halloysite powder; and the hydrogen evolution inhibitor is one or more of indium chloride, copper chloride, indium sulfate, and copper sulfate.

5. The manufacturing method of the to-be-filled zinc-manganese secondary battery according to claim 2 , wherein the alcohol-water mixed solvent is a mixed solvent of water with isopropanol, propylene glycol, or ethanol, with a volume percentage of the water to alcohol of (40% to 80%):(20% to 60%); and a solid content of the uniform gel mass is 40% to 60%.

6. The manufacturing method of the to-be-filled zinc-manganese secondary battery according to claim 2 , wherein when the millimeter-sized granules (E) are roll-pressed once through the horizontal hot roller press at a hot rolling temperature of 55° C. to 95° C., a thickness of the negative electrode film F of 90 μm to 200 μm is achieved.

7. The manufacturing method of the to-be-filled zinc-manganese secondary battery according to claim 2 , wherein when the semi-dry negative electrode films (F) are thermally laminated with the glue-coated stainless steel foil, the glue-coated stainless steel foil is sandwiched between two semi-dry nega

Assignees

• Univ Jiangsu

Inventors

• Zhou Haitao
• Gao Hongquan
• Wu Jianchun
• Zhou Haiyun
• Yao Shengjie
• Zhu Hongwen
• Yan Rongfei

Classifications

• H01M2300/0011

  Sulfuric acid-based · CPC title

• H01M10/288

  Processes for forming or storing electrodes in the battery container · CPC title

• H01M10/26

  Selection of materials as electrolytes · CPC title

• H01M10/049

  Processes for forming or storing electrodes in the battery container · CPC title

• H01M10/0431 Primary

  Cells with wound or folded electrodes (H01M10/045 takes precedence) · CPC title