Low concentration additives for iron negative electrodes

Patent metadata

Field	Value
Publication number	US-2025132320-A1
Application number	US-202418922247-A
Country	US
Kind code	A1
Filing date	Oct 21, 2024
Priority date	Oct 19, 2023
Publication date	Apr 24, 2025
Grant date	—

Abstract

According to an aspect, an electrochemical cell may include an electrolyte and an anode in the electrolyte, the anode including an iron-containing active material, at least one of the anode and the electrolyte including an additive reactive to inhibit hydrogen evolution in a charge state and in a resting state of the electrochemical cell, and the additive in a concentration greater than about 10 and less than about 10,000 atoms of additive per million atoms iron of the iron-containing active material.

First claim

What is claimed is:

1 . An electrochemical cell comprising:
an electrolyte; and an anode in the electrolyte, the anode including an iron-containing active material, at least one of the anode and the electrolyte including an additive reactive to inhibit hydrogen evolution in a charge state and in a resting state of the electrochemical cell, and the additive in a concentration greater than about 10 and less than about 10,000 atoms of additive per million atoms iron of the iron-containing active material.

2 . The electrochemical cell of claim 1 , wherein the additive includes one or more non-ferrous metal components.

3 . The electrochemical cell of claim 2 , wherein the one or more non-ferrous metal components include Sb, Bi, Cd, Hg, In, Cu, Pb, Ga, Sc, Ge, or combinations thereof.

4 . The electrochemical cell of claim 2 , wherein each of the one or more non-ferrous metal components is in one of an elemental form, an oxide, a hydroxide, an oxyhydroxide, a nitrate, an acetate, a sulfate, a phosphate, a carbonate, a chloride, or a sulfide form.

5 . The electrochemical cell of claim 2 , wherein the additive includes an alloy of the one or more non-ferrous metal components.

6 . The electrochemical cell of claim 1 , wherein the additive is dispersed in the electrolyte.

7 . The electrochemical cell of claim 1 , wherein the additive is supported on the anode, and the additive is dissolvable from the anode into the electrolyte during cycling of the electrochemical cell between a charge mode and a discharge mode.

8 . The electrochemical cell of claim 1 , wherein the additive is wetted on the iron-containing active material of the anode.

9 . The electrochemical cell of claim 1 , wherein the additive is disposed in the anode, and a highest concentration of the additive is along a surface of the anode.

10 . The electrochemical cell of claim 1 , wherein the iron-containing active material of the anode at least partially defines a porous structure.

11 . The electrochemical cell of claim 1 , wherein the electrolyte includes potassium hydroxide (KOH), sodium hydroxide, lithium hydroxide (LiOH), or a combination thereof.

12 . The electrochemical cell of claim 1 , wherein the additive reduces a rate of self-discharge of the electrochemical cell by at least 10 percent compared to the rate of self-discharge of the electrochemical cell without the additive.

13 . The electrochemical cell of claim 1 , wherein a mean percentage capacity of the electrochemical cell lost per day of is greater than zero and less than 4 percent.

14 . The electrochemical cell of claim 1 , wherein specific hydrogen current density of the electrochemical cell is greater than zero and less than 0.5 mA/g, measured over a 48 hour rest at top of charge of the electrochemical cell.

15 . The electrochemical cell of claim 1 , wherein the additive is substantially uniformly distributed in the anode with volumetric concentration of the additive in the anode varying by less than ±20 percent within the anode.

16 . The electrochemical cell of claim 1 , further comprising a positive electrode in ionic communication with the anode via the electrolyte.

17 . A method of fabricating an electrode for an electrochemical cell, the method comprising:
forming a feedstock including an iron-containing active material and at least one of an additive or a precursor of the additive, the additive reactive to inhibit hydrogen evolution from the electrode under electrochemical cycling; processing the feedstock into a composite, the additive distributed relative to the iron-containing active material in the composite, and additive in a concentration greater than about 10 and less than about 10,000 atoms of additive per million atoms of iron in the composite; and shaping the composite into a green body of the electrode.

18 . A method of fabricating an electrode for an electrochemical cell, the method comprising:
forming a green body including an iron-containing active material; positioning an additive on at least one surface of the green body, the additive reactive to inhibit hydrogen evolution from the electrode under electrochemical operation; and with the additive positioned on the at least one surface of the green body, wicking the additive into the green body.

19 . A method of static discharge testing of an electrochemical cell, the method comprising:
cycling the electrochemical cell through at least two baseline cycles, each baseline cycle including charging the electrochemical cell from a lower voltage limit to a predetermined target capacity and discharging the electrochemical cell from the predetermined target capacity to the lower voltage limit; measuring a first Coulombic efficiency of the electrochemical cell following the at least two baseline cycles; cycling the electrochemical cell through a comparison cycle including
charging the electrochemical cell from the lower voltage limit to the predetermined target capacity,
with the electrochemical cell charged to the predetermined target capacity, interrupting electric current to the electrochemical cell for a predetermined rest period, and
at the end of the predetermined rest period, discharging the electrochemical cell to the lower voltage limit;
measuring a second Coulombic efficiency following the comparison cycle; and based on the first Coulombic efficiency and the second Coulombic efficiency, determining a change in discharge capacity of the electrochemical cell.

Assignees

• Form Energy Inc

Inventors

• Norman Zachariah
• Thompson Annelise Christine
• Kyriakides Cleo
• Gibson Michael Andrew
• Frisco Sarah
• Hooke David
• Choudhury Rishav
• Groschner Catherine Kingston
• Stringer Craig

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M2004/027

  Negative electrodes · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M4/628

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

• H01M4/38 Primary

  of elements or alloys · CPC title