Metal-air battery and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-2017279173-A1
Application number	US-201615354539-A
Country	US
Kind code	A1
Filing date	Nov 17, 2016
Priority date	Mar 25, 2016
Publication date	Sep 28, 2017
Grant date	—

Abstract

A metal-air battery includes an anode portion including a metal; a cathode portion including a porous layer, wherein the porous layer includes a reduced non-stacked graphene oxide; and an electrolyte disposed between the anode portion and the cathode portion.

First claim

What is claimed is:

1 . A metal-air battery comprising:
an anode portion comprising a metal; a cathode portion comprising a porous layer, wherein the porous layer comprises a reduced non-stacked graphene oxide; and an electrolyte disposed between the anode portion and the cathode portion.

2 . The metal-air battery of claim 1 , wherein the porous layer consists of the reduced non-stacked graphene oxide.

3 . The metal-air battery of claim 2 , wherein the reduced non-stacked graphene oxide comprises adjacent layers which are separated by a gap of about 1 nanometer to about 0.15 micrometer.

4 . The metal-air battery of claim 3 , wherein the porous layer has a porosity of 70 volume percent to 99 volume percent.

5 . The metal-air battery of claim 1 , wherein the reduced non-stacked graphene oxide has a crumpled shape.

6 . The metal-air battery of claim 1 , wherein the reduced non-stacked graphene oxide is derived from a non-stacked graphene oxide having a ratio of C—O bonds to C═C bonds of about 0.5 or less.

7 . The metal-air battery of claim 6 , wherein the ratio of C—O bonds to C═C bonds of the graphene oxide ranges from about 0.1 to about 0.5, and the graphene oxide has a porous structure.

8 . The metal-air battery of claim 1 , wherein the porous layer comprises a plurality of reduced graphene oxide layers, wherein the porous layer has a wave shape, and wherein adjacent reduced graphene oxide layers are separated by a gap.

9 . The metal-air battery of claim 8 , wherein an interval between the adjacent reduced graphene oxide layers ranges from about 1 nanometer to about 0.15 micrometers, and wherein the plurality of reduced graphene oxide layers comprises a porous structure.

10 . The metal-air battery of claim 1 , wherein the porous layer comprises a binder-free material layer.

11 . The metal-air battery of claim 1 , wherein the porous layer comprises a binder.

12 . The metal-air battery of claim 1 , wherein a porosity of the porous layer ranges from about 70 volume percent to about 95 volume percent, based on a total volume of the porous layer.

13 . The metal-air battery of claim 1 , wherein a specific surface area of the porous layer ranges from about 100 square meters per gram to about 600 square meters per gram.

14 . The metal-air battery of claim 1 , wherein the cathode portion comprises
a cathode layer, and a gas diffusion layer on at least one surface of the cathode layer, wherein at least one of the cathode layer and the gas diffusion layer includes the porous layer.

15 . The metal-air battery of claim 14 , wherein a supporting member supporting the gas diffusion layer comprises the reduced graphene oxide and an additional material, and wherein the additional material comprises a carbon sphere, a carbon rod, a hollow carbon sphere, a hollow carbon rod, an aerogel, a metal oxide sphere, a metal oxide rod, a hollow metal oxide sphere, a hollow metal oxide rod, or a combination thereof.

16 . The metal-air battery of claim 14 , wherein a thickness of the cathode layer ranges from about 1 micrometer to about 100 micrometers.

17 . The metal-air battery of claim 14 , wherein a thickness of the gas diffusion layer ranges from about 1 micrometer to about 30 micrometers.

18 . The metal-air battery of claim 1 , wherein the metal-air battery has a cathode specific capacity of about 250 milliampere hours per gram or greater.

19 . A method of manufacturing a metal-air battery, the method comprising:
providing an anode portion comprising a metal; forming a cathode portion configured for using oxygen as an active material, wherein the cathode portion comprises a porous layer; and providing an electrolyte between the anode portion and the cathode portion, wherein the forming of the cathode portion comprises
forming a non-stacked graphene oxide using an anti-solvent precipitation method,
reducing the non-stacked graphene oxide to form a reduced non-stacked graphene oxide, and
disposing the reduced non-stacked graphene oxide to form the porous layer to manufacture the metal-air battery.

20 . The method of claim 19 , wherein the forming of the non-stacked graphene oxide using an anti-solvent precipitation method comprises:
dissolving the graphene oxide in a polar solvent to form a solution; adding a non-polar solvent to the solution to precipitate the non-stacked graphene oxide; and drying the precipitated non-stacked graphene oxide.

21 . The method of claim 19 , wherein the reducing of the non-stacked graphene oxide comprises heating the non-stacked graphene oxide in a mixed gas atmosphere of hydrogen and nitrogen to form the reduced non-stacked graphene oxide.

22 . The method of claim 21 , wherein the heating of the non-stacked graphene oxide comprises:
performing a first thermal treatment on the non-stacked graphene oxide at a temperature in a range of about 150° C. to about 500° C.; and then performing a second thermal treatment on the non-stacked graphene oxide at a temperature in a range of about 700° C. to about 1200° C.

23 . The method of claim 19 , wherein the reducing of the non-stacked graphene oxide comprises contacting the non-stacked graphene oxide and a reducing agent.

24 . The method of claim 19 , wherein the forming of the porous layer comprises:
dispersing the reduced non-stacked graphene oxide in a solvent to form a dispersion; and vacuum filtering the dispersion to form a free-standing film comprising the reduced non-stacked graphene oxide.

25 . The method of claim 24 , wherein the dispersing of the reduced non-stacked graphene oxide in the solvent comprises at least one of:
adding a dispersing agent to the solvent to disperse the reduced non-stacked graphene oxide; and sonicating a combination of the solvent and the reduced non-stacked graphene oxide.

26 . The method of claim 19 , wherein the porous layer comprises a binder-free material layer.

27 . The method of claim 19 , wherein the porous layer consists of the reduced non-stacked graphene oxide.

28 . The method of claim 19 , wherein the porous layer comprises a binder.

29 . The method of claim 19 , wherein a ratio of C—O bonds to C═C bonds of the non-stacked graphene oxide is about 0.5 or less.

30 . The method of claim 19 , wherein the porous layer comprises a plurality of reduced non-stacked graphene oxide layers,
wherein the porous layer has a wave shape, and wherein adjacent reduced non-stacked graphene oxide layers are separated by a gap.

31 . The method of claim 18 , wherein the cathode portion comprises
a cathode layer, and a gas diffusion layer contacting the cathode layer, wherein at least one of the cathode layer and the gas diffusion layer comprises the porous layer.

Assignees

• Samsung Electronics Co Ltd

Inventors

• Jung Insun
• Kwon Hyukjae
• Kim Mokwon
• Kim Junghwa
• Byun Sunjung
• Yu Daeun
• Yun Dongjin
• Lee Hyangsook

Classifications

• H01M4/8605

  Porous electrodes · CPC title

• H01M12/06

  with one metallic and one gaseous electrode · CPC title

• H01M4/96

  Carbon-based electrodes · CPC title

• H01M2004/8689

  Positive electrodes · CPC title

• H01M4/8882

  Heat treatment, e.g. drying, baking · CPC title