Sodium ion batteries and methods of manufacture thereof

Patent metadata

Field	Value
Publication number	US-2025105341-A1
Application number	US-202318471362-A
Country	US
Kind code	A1
Filing date	Sep 21, 2023
Priority date	Sep 21, 2023
Publication date	Mar 27, 2025
Grant date	—

Abstract

A sodium ion battery includes an anode, a cathode, a separator and an electrolyte. The anode includes an anode active layer, the cathode includes a cathode active layer and the separator includes a porous film. At least one of the anode active layer, the cathode active layer or the separator have an anode zeolite layer, a cathode zeolite layer or a separator zeolite layer respectively disposed thereon.

First claim

What is claimed is:

1 . A sodium ion battery comprising:
an anode; where the anode comprises an anode active layer; a cathode; where the cathode comprises a cathode active layer; and a separator; where the separator comprises a porous film; where at least one of the anode active layer, the cathode active layer or the separator have an anode zeolite layer, a cathode zeolite layer or a separator zeolite layer respectively disposed thereon; and an electrolyte.

2 . The sodium ion battery of claim 1 , where an anode zeolite layer, a cathode zeolite layer and a separator zeolite layer all have a same composition.

3 . The sodium ion battery of claim 1 , where an anode zeolite layer, a cathode zeolite layer and a separator zeolite layer all have a different composition.

4 . The sodium ion battery of claim 1 , where a zeolite used in the anode zeolite layer, the cathode zeolite layer and the separator zeolite layer is sodium zeolite A-NaA, sodium zeolite X—NaX, sodium zeolite Y—NaY, sodium zeolite ZSM-5, sodium clinoptilolite, or a combination thereof.

5 . The sodium ion battery of claim 1 , wherein the anode active layer or the cathode active layer have zeolite particles dispersed therein.

6 . The sodium ion battery of claim 1 , where the anode zeolite layer, the cathode zeolite layer and the separator zeolite layer all comprise zeolite particles having a particle size of 100 nanometers (nm) to 5 micrometers (μm), with a D 50 value of 300 nanometers.

7 . The sodium ion battery of claim 6 , wherein the zeolite particles are subjected to a sodium ion exchange process prior to being used in the sodium ion battery.

8 . The sodium ion battery of claim 1 , where the anode zeolite layer or the cathode zeolite layer have a porosity of 20 to 40 volume percent based on a total volume of the anode zeolite layer or the cathode zeolite layer, respectively.

9 . The sodium ion battery of claim 1 , where the separator zeolite layer has a broader porosity range than either the anode zeolite layer or the cathode zeolite layer.

10 . The sodium ion battery of claim 1 , where the separator zeolite layer has a porosity of 30 to 70 volume percent based on a total volume of the separator zeolite layer.

11 . The sodium ion battery of claim 5 , where the zeolite particles in the anode active layer or the cathode active layer are present in an amount of up to 10 wt %, based on a total weight of the anode active layer or a total weight of the cathode active layer.

12 . The sodium ion battery of claim 1 , where the anode zeolite layer or the cathode zeolite layer have a thickness of 500 nanometers to 10 micrometers.

13 . The sodium ion battery of claim 1 , where the separator zeolite layer has a thickness of 1 to 10 micrometers.

14 . The sodium ion battery of claim 1 , where the separator zeolite layer is disposed on opposing surfaces of the porous film.

15 . A method of manufacturing a sodium ion battery comprising:
disposing an anode zeolite layer on an anode active layer that is in contact with an anode current collector; or disposing a cathode zeolite layer on a cathode active layer that is in contact with a cathode current collector; or disposing a separator zeolite layer on a separator that is disposed between the cathode active layer and the anode active layer; and disposing the anode active layer, the cathode active layer and the separator in a housing.

16 . The method of claim 15 , further comprising disposing zeolite particles in the anode active layer or the cathode active layer.

17 . The method of claim 15 , further comprising disposing an anode zeolite layer on an anode active layer that is in contact with an anode current collector and disposing a cathode zeolite layer on a cathode active layer that is in contact with a cathode current collector.

18 . The method of claim 17 , further comprising disposing a separator zeolite layer on a separator that is disposed between the cathode active layer and the anode active layer.

19 . The method of claim 15 , wherein the anode zeolite layer or the cathode zeolite layer have a porosity of 20 to 40 volume percent based on a total volume of the anode zeolite layer or the cathode zeolite layer, respectively.

20 . The method of claim 15 , wherein the separator zeolite layer has a porosity of 30 to 70 volume percent based on a total volume of the separator zeolite layer.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Xiao Xingcheng
• Dai Fang
• Cai Mei

Classifications

• H01M50/434

  Ceramics · CPC title

• H01M50/489

  Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties · CPC title

• H01M50/449

  having a layered structure · CPC title

• H01M50/44

  Fibrous material · CPC title

• H01M10/054 Primary

  Accumulators with insertion or intercalation of metals other than lithium, e.g. with magnesium or aluminium · CPC title