Feedstocks and methods for fabrication of iron electrodes using sulfide-containing particles

Patent metadata

Field	Value
Publication number	US-2024372073-A1
Application number	US-202418435597-A
Country	US
Kind code	A1
Filing date	Feb 7, 2024
Priority date	Feb 7, 2023
Publication date	Nov 7, 2024
Grant date	—

Abstract

According to one aspect, a feedstock for fabricating an iron electrode of an electrochemical cell may include iron-containing particles of a first material, sulfide-containing particles of a second material different from the first material, and a barrier material different from each of the first material and the second material, the barrier material at least partially physically separating the sulfide-containing particles from the iron particles, the at least partial physical separation of the iron-containing particles from the sulfide-containing particles maintainable by the barrier material at temperatures at which iron in the iron-containing particles bonds in the solid state.

First claim

1 . A feedstock for fabricating an iron electrode of an electrochemical cell, the feedstock comprising:
iron-containing particles of a first material; sulfide-containing particles of a second material different from the first material; and a barrier material different from each of the first material and the second material, the barrier material at least partially physically separating the sulfide-containing particles from the iron-containing particles, the at least partial physical separation of the iron-containing particles from the sulfide-containing particles maintainable by the barrier material at temperatures at which iron in the iron-containing particles bonds in the solid state.

2 - 16 . (canceled)

17 . The feedstock of claim 1 , wherein the barrier material is a coating on the iron-containing particles, on the sulfide-containing particles, or on a combination thereof.

18 - 31 . (canceled)

32 . A method of fabricating an iron electrode for an electrochemical cell, the method comprising:
forming a feedstock including a barrier material, iron-containing particles of a first material, and sulfide-containing particles of a second material, the barrier material at least partially physically separating the sulfide-containing particles from the iron-containing particles in the feedstock, and the first material, the second material, and the barrier material each differing from one another; and bonding iron in the iron-containing particles in the solid state via thermal processing as the barrier material at least partially maintains physical separation of the iron-containing particles from the sulfide-containing particles.

33 . The method of claim 32 , wherein forming the feedstock includes creating a coating of the barrier material on the iron-containing particles, on the sulfide-containing particles, or on a combination thereof.

34 . The method of claim 33 , wherein creating the coating includes a solid-phase coating process.

35 . The method of claim 34 , wherein the solid-phase coating process includes physically abrading the barrier material against the iron-containing particles and/or against the sulfide-containing particles.

36 . The method of claim 33 , wherein creating the coating includes a gas-phase coating process.

37 - 38 . (canceled)

39 . The method of claim 33 , wherein creating the coating includes a liquid-phase coating process.

40 . (canceled)

41 . The method of claim 33 , wherein creating the coating of the barrier material includes chemical precipitation of the barrier material from a solution.

42 . The method of claim 33 , wherein creating the coating of the barrier material includes at least partially covering the iron-containing particles, the sulfide-containing particles, or a combination thereof with a precursor material and processing the precursor material into the barrier material.

43 . (canceled)

44 . The method of claim 33 , wherein forming the feedstock includes forming the sulfide-containing particles from a metallic precursor and a sulfur precursor such that the sulfide-containing particles are nanoparticles.

45 . The method of claim 44 , wherein the metallic precursor is zinc carboxylate.

46 - 47 . (canceled)

48 . The method of claim 44 , wherein formation of the metallic precursor and the sulfur precursor into the sulfide-containing particles is carried out in an organic solvent.

49 . (canceled)

50 . The method of claim 33 , wherein the barrier material includes an oxide and creating the coating of the barrier material includes oxidizing the sulfide-containing particles to form a layer of oxide on the sulfide-containing particles.

51 - 52 . (canceled)

53 . The method of claim 32 , wherein forming the feedstock includes producing the barrier material from one or more impurities in the sulfide-containing particles.

54 . (canceled)

55 . The method of claim 32 , wherein the barrier material includes iron sulfide (FeS), and forming the feedstock includes reacting sulfide-containing particles with iron of the iron-containing particles to form FeS of the barrier material.

56 . (canceled)

57 . The method of claim 32 , wherein bonding iron in the iron-containing particles in the solid state via thermal processing is carried out at temperatures greater than 600° C. and less than about 1200° C.

58 . The method of claim 32 , wherein bonding iron in the iron-containing particles in the solid state via thermal processing is carried out in a gaseous environment including hydrogen, carbon monoxide gas, or a combination thereof.

59 . (canceled)

60 . The method of claim 32 , wherein bonding iron in the iron-containing particles in the solid state via thermal processing is carried out in a gaseous environment including one or more inert gases.

61 . (canceled)

62 . The method of claim 32 , wherein bonding iron in the iron-containing particles in the solid state via thermal processing is carried out in a vacuum environment.

63 . (canceled)

Assignees

• Form Energy Inc

Inventors

• Gibson Michael Andrew
• Perkins Nicholas Reed
• Nation Leah Nicole
• Manser Joseph Stephen
• Norman Zachariah
• Thompson Annelise Christine

Classifications

• H01M4/38

  of elements or alloys · CPC title

• H01M4/366

  as layered products · CPC title

• H01M4/0407

  by coating on an electrolyte layer · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M4/628

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