Solid state additives for iron negative electrodes

Patent metadata

Field	Value
Publication number	US-2024063398-A1
Application number	US-202318451458-A
Country	US
Kind code	A1
Filing date	Aug 17, 2023
Priority date	Aug 17, 2022
Publication date	Feb 22, 2024
Grant date	—

Abstract

According to one aspect, an additive for an iron negative electrode of an alkaline electrochemical cell may include a powder of discrete granules including agglomerated particles, the agglomerated particles including at least one metal sulfide.

First claim

What is claimed is:

1 . An additive for an iron negative electrode of an alkaline electrochemical cell, the additive comprising:
a powder of discrete granules including agglomerated particles, the agglomerated particles including at least one metal sulfide.

2 . The additive of claim 1 , wherein the at least one metal sulfide of the agglomerated particles is greater than 50 wt % of the discrete granules.

3 . The additive of claim 1 , wherein the discrete granules have a mean particle size of greater than about 30 microns and less than about 800 microns on a weight percentage basis.

4 . The additive of claim 1 , wherein the discrete granules of the agglomerated particles of the at least one metal sulfide have a median pore size of greater than about 75 nanometers and less than about 15 microns as determined by mercury intrusion porosimetry.

5 . The additive of claim 1 , wherein the discrete granules have a first average apparent density, the particles including the at least one metal sulfide have a second average apparent density, and the first average apparent density is less than the second average apparent density.

6 . The additive of claim 1 , wherein the discrete granules have a friability of less than about 10% weight loss according to European Pharmacopoeia 2.9.41.-2 (Method B).

7 . The additive of claim 1 , wherein solid-state bonding holds at least some of the agglomerated particles together in the discrete granules possess solid state bonding between the agglomerated particles.

8 . The additive of claim 1 , wherein the discrete granules include a binder, and at least some of the agglomerated particles of the discrete granules are bonded by the binder.

9 . The additive of claim 1 , wherein the at least one metal sulfide includes zinc sulfide (ZnS).

10 . The additive of claim 9 , wherein the powder of the discrete granules is greater than or equal to 90% by weight zinc sulfide (ZnS).

11 . The additive of claim 1 , wherein the agglomerated particles of the discrete granules have surface-connected porosity.

12 . An iron negative electrode for an alkaline electrochemical cell, the iron negative electrode comprising:
a first powder including an iron active material; and a second powder including the additive of claim 1 , the first powder and the second powder forming a powder blend in which the second powder is dispersed relative to the first powder.

13 . A method of making an additive for an iron negative electrode of an alkaline electrochemical cell, the method comprising:
forming a feedstock including a particulate material having a predetermined composition; and processing the feedstock including the particulate material into a powder of discrete granules including agglomerated particles of the particulate material, the agglomerated particles including at least one metal sulfide.

14 . The method of claim 13 , wherein processing the feedstock of the particulate material includes solid-state bonding of the particulate material.

15 . The method of claim 13 , wherein forming the feedstock includes introducing at least one polymeric binder to the particulate material.

16 . The method of claim 15 , wherein processing the feedstock into the discrete granules includes pyrolyzing the at least one polymeric binder to form a graphitized film on the particulate material.

17 . The method of claim 16 , wherein, with the at least one polymeric binder introduced to the particulate material, the particulate material is thermomechanically bonded in a processing atmosphere including hydrogen gas.

18 . The method of claim 17 , wherein forming the feedstock of the particulate material includes mixing at least two metal sulfides together in a predetermined weight ratio relative to one another.

19 . The method of claim 18 , wherein the at least two metal sulfides include zinc sulfide (ZnS) and iron sulfide (FeS).

20 . The method of claim 13 , wherein the particulate material includes particles of the at least one metal sulfide includes particles of zinc sulfide (ZnS).

Assignees

• Form Energy Inc

Inventors

• Hooke David
• Gibson Michael Andrew
• Thompson Annelise Christine
• Pantano Joseph Anthony
• Syvertsen Marc Louis

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M4/628 Primary

  Inhibitors, e.g. gassing inhibitors, corrosion inhibitors · CPC title

• H01M4/38

  of elements or alloys · CPC title

• H01M4/248

  Iron electrodes · CPC title

• H01M2004/027

  Negative electrodes · CPC title