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JP-2026514476-A - Method for manufacturing sodium or potassium ion battery cells

JP2026514476AJP 2026514476 AJP2026514476 AJP 2026514476AJP-2026514476-A

Abstract

This disclosure generally relates to a method for producing a sodium or potassium ion battery cell containing a Prussian blue analog (PBA) as a cathode active material. This disclosure also relates to a sodium or potassium ion battery produced by this method.

Inventors

  • モーゲンセン、ロニー
  • マリノフスキース、パウリウス
  • ヘドマン、ヨナス

Assignees

  • アルトリス エービー

Dates

Publication Date
20260511
Application Date
20240416
Priority Date
20230419

Claims (15)

  1. A method for manufacturing a sodium or potassium ion battery cell, a) To provide a slurry containing a Prussian blue analog, wherein the Prussian blue analog may be present in a first hydration phase and a second dehydration phase, and the slurry contains the first hydration phase of the Prussian blue analog. b) Applying the slurry to the current collector to form a cathode, c) Assembling the cathode with the anode and separator to form an electrode stack, d) Drying the electrode stack under conditions that allow the Prussian blue analog to convert from the first hydrated phase to the second dehydrated phase, e) Placing the electrode stack inside the battery casing, f) Adding an electrolyte to the battery casing, g) sealing the battery casing to form a battery cell, A method wherein steps e) to g) are carried out in an atmosphere with a dew point temperature in the range of -40°C to -80°C, and the process time for carrying out steps e) to g) is less than 7 hours, preferably less than 5 hours.
  2. The method according to claim 1, wherein steps e) to g) are performed in an atmosphere with a dew point temperature in the range of -45°C to -70°C.
  3. The method according to any one of claims 1 and 2, wherein the process time for carrying out steps e) to g) is 10 minutes to less than 3 hours, preferably 15 minutes to 2.5 hours.
  4. The method according to any one of claims 1 to 3, wherein steps a) to c) of the above method are performed under ambient conditions.
  5. The method according to any one of claims 1 to 4, wherein the Prussian blue analog is present in the first hydration phase in steps a) to c) of the method.
  6. The method according to any one of claims 1 to 5, wherein the drying step d) is performed at a drying temperature t1 of 110 to 300°C.
  7. The method according to any one of claims 1 to 6, wherein the drying step d) is performed under a pressure below the ambient pressure.
  8. The process according to any one of claims 1 to 7, wherein the separator has a melting temperature t2 that is higher than the drying temperature t1.
  9. The Prussian blue analog has the formula A a M b [M' c (CN) 6 ] d , where A is sodium or potassium. The method according to any one of claims 1 to 8, wherein 1 < a ≤ 2, M and M' are transition metals, preferably selected from iron and/or manganese, and 0 < b < 2, 1 < c < 2, and 1 < d < 2.
  10. The method according to any one of claims 1 to 9, wherein the Prussian blue analog is Prussian white having the formula A a Fe [Fe(CN) 6 ], where A is sodium or potassium, and 1.8 < a ≤ 2, preferably 1.9 < a ≤ 2.
  11. The method according to any one of claims 1 to 10, wherein the step of applying the slurry to a current collector comprises coating the current collector with the slurry in a coating weight of 5 mg/ cm² to 70 mg/ cm² , preferably 10 mg/cm² to 40 mg/ cm² .
  12. A sodium or potassium ion battery cell manufactured according to the method described in any one of claims 1 to 11.
  13. The sodium or potassium ion battery cell according to claim 12, wherein the battery cell has an electrochemical cycle curve in which there is no voltage plateau greater than 3.7V with respect to Na + /Na or K + /K.
  14. The sodium or potassium ion battery cell according to claim 12 or 13, wherein the battery cell has an electrochemical cycle curve that exhibits one voltage plateau between 3.2 and 3.7 V with respect to Na + /Na or K + /K, and there are no additional voltage plateaus in the electrochemical cycle curve.
  15. The sodium or potassium ion battery cell according to any one of claims 12 to 14, wherein the energy efficiency of the battery cell is at least 80% over the first 25 cycles.

Description

This disclosure generally relates to a method for producing sodium or potassium ion battery cells containing a Prussian blue analog (PBA) as the cathode active material. This disclosure also relates to sodium or potassium ion battery cells produced by this method. Lithium-ion batteries dominate the rechargeable battery market. However, this technology has drawbacks, particularly due to the relatively limited availability of lithium resources. While superior to previous generations of secondary battery technology, lithium-ion batteries are not considered environmentally friendly and are costly from a recycling perspective. These drawbacks have triggered the search for alternatives to lithium-ion batteries. Sodium or potassium-ion batteries present an attractive alternative and are also a viable means of supporting renewable energy sources for purposes such as load leveling and excess energy storage. The performance of sodium or potassium ion batteries largely depends on the properties of the electrode materials. A typical process for manufacturing electrodes, such as cathodes, involves mixing an active material with a solvent, conductive additives, and a binder to form a slurry. The slurry is then coated onto a current collector to form the cathode. The cathode may then be assembled with any other components used to form a battery, such as an anode and a separator. In conventional battery manufacturing, all process steps typically need to be carried out in a dry room. A dry room is a room where the moisture content of the air is controlled to a specific level. Exposure of batteries or any of their components to moisture during assembly can lead to a decrease in quality, such as reduced charging capacity and overall performance. Prussian blue analog (PBA) cathode materials stand out as promising cathode materials for use in sodium or potassium ion batteries. Prussian blue analogs possess a unique crystalline structure with an open three-dimensional framework and large interstitial voids, allowing them to store sodium (and potassium) ions. When PBA is used as a cathode active material, drying is particularly important in battery cells because it is necessary to remove any water present in the PBA structure in order for the active material to fully utilize its capacity. The presence of water can adversely affect the electrochemical potential and cycle stability of battery cells containing PBA as a cathode material. Therefore, when used in final battery cells, it is essential to remove any water present in the PBA material. However, even after water is removed from the PBA material, it still retains a strong affinity for water. PBA is extremely hygroscopic and can rapidly transition from anhydrous to hydrated upon exposure to air or moisture. Therefore, the manufacture of battery cells containing PBA-containing cathodes is a cumbersome and difficult process. While conventional battery manufacturing can utilize dry rooms, dry rooms such as those used in lithium-ion battery production are not always sufficient to guarantee that PBA material remains in its anhydrous form, resulting in an increased risk of cathode decomposition. Furthermore, dry rooms are generally not a convenient environment for personnel to work in. Therefore, there is a need to provide an improved method for manufacturing sodium or potassium ion batteries that is simpler, cheaper, and more convenient from the perspective of the working environment. Furthermore, this method should be suitable for the large-scale manufacture of sodium or potassium ion batteries. In consideration of the aforementioned and other drawbacks of the prior art, the object of this disclosure is to provide improvements relating to sodium or potassium ion batteries, and in particular to providing a simple and inexpensive manufacturing method for producing such batteries on a large industrial scale. According to a first aspect of this disclosure, a method for manufacturing a sodium or potassium ion battery cell, a) To provide a slurry containing a Prussian blue analog, wherein the Prussian blue analog may be present in a first hydration phase and a second dehydration phase, and the slurry contains the first hydration phase of the Prussian blue analog. b) Applying the slurry to the current collector to form a cathode, c) Assembling the cathode with the anode and separator to form an electrode stack, d) Drying the electrode stack under conditions that allow the Prussian blue analog to convert from the first hydrated phase to the second dehydrated phase, e) Placing the electrode stack inside the battery casing, f) Adding an electrolyte to the battery casing, g) sealing the battery casing to form a battery cell, A method is provided in which steps e) to g) are carried out in an atmosphere with a dew point temperature in the range of -40°C to -80°C, and the process time for carrying out steps e) to g) is less than 7 hours, preferably less than 5 hours. Prussian blue analogs (PBA)