cathode

Abstract

Disclosed is a cathode material suitable for use in an aluminum-ion battery, wherein the cathode material comprises a main group element nitride and a main group element oxide or a Group 1 to 13 element oxide. The nitride is preferably a two-dimensional layered material. Preferably, the ratio of main group element nitride to oxide is between 5:95 and 95:5 (by weight).

Description

TECHNICAL FIELD

[0001] The present invention relates to improved cathodes for aluminum-ion batteries, aluminum-ion batteries comprising the improved cathodes, and methods of manufacturing cathodes for aluminum-ion batteries. BACKGROUND

[0003] Batteries are an important source of stored electrical energy and are widely used in many different types of devices and applications.

[0004] The performance of batteries is greatly dependent on many factors, including the physico-chemical properties of the materials used to make the electrodes of the battery; and the electrolyte solution. These factors affect battery performance by reducing the battery voltage, coulombic efficiency, reducing the rate capability (maximum charge / discharge rate) of the cell, and the stability of the cell.

[0005] Many different types of batteries are in use, including lead-acid batteries, nickel-cadmium based batteries, and ion batteries. Common to all of these battery types is the presence of a cathode, an anode, and an electrolyte solution, which can be connected to form an electrical circuit and used to provide energy to a device.

[0006] In recent years, there has been a surge of interest in ion batteries for commercial applications due to the benefits that these batteries can provide. Currently, lithium-ion batteries (LIBs) have a high charge density, a low self-discharge tendency, a low memory effect, a low charging time, and low maintenance compared to other rechargeable batteries such as NiCd, nickel metal hydride (NiMH), etc.

[0007] LIBs have been widely used in devices such as electric vehicles, mobile phones, and other electronic devices. However, they have not been widely used for grid energy storage. The LIB industry uses 42% of the global cobalt production, a metal that is essential for lithium-ion batteries. Lithium metal is reactive, and the transportation of its raw materials requires extra care to prevent any physical or electrical harm. Despite significant cost reductions in recent years, LIBs are still significantly more expensive than other batteries. In addition, LIBs can experience thermal runaway. If this happens, the electrolyte warms up during discharge to cause an unwanted exothermic reaction. The additional heat generated in the battery cell subsequently leads to electrolyte leakage, gas leakage, and / or explosion. LIBs can also form metal lithium dendrites, which can puncture the battery separator and cause damage and thermal runaway. LIBs also often use highly flammable electrolytes, which enhance the combustible nature of LIBs.

[0008] Lead-acid batteries are another commonly used battery type and use lead dioxide as the cathode material. Lead-acid batteries are commonly used in electrical energy storage systems, such as in motor vehicles; industrial power, trucks, mining vehicles; stationary applications, emergency and backup power. However, lead-acid batteries present a risk of fire, explosion, and electric shock. They charge slowly and self-discharge if not used for a period of time. Despite their widespread use, lead-acid batteries present many problems, such as: evolution of hydrogen and oxygen gas; sulfuric acid leakage; sulfation of the battery, which reduces the electrical efficiency and battery life; freezing of the battery at low discharge levels; loss of active material in the electrodes; and damage to the electrodes. Furthermore, lead is a heavy metal and is toxic to humans and the environment.

[0009] Nickel-based batteries, such as NiCd and NiMH batteries, use nickel oxyhydroxide (NiOOH) as the cathode material. NiMH batteries are used in hybrid electric vehicles and military communications. However, despite the good cycle life, long shelf life, and operation over a wide range of temperatures of NiMH batteries, the production cost of the metal hydride alloy is high, such that this type of battery is expensive. NiCd batteries provide good performance in harsh conditions and are able to withstand long periods of deep discharge. However, the material cost is high. Furthermore, cadmium is highly toxic to the environment, such that its disposal after the battery has expired is a problem. This has led to its reduced use (even banned) in some areas, such as in Europe.

[0010] In contrast, rechargeable aluminum-ion batteries (AIBs) offer a potential alternative to lithium-ion batteries. Aluminum is a trivalent metal, with three valence electrons in its outermost shell. The trivalency of aluminum, compared to elements with fewer valence electrons, such as lithium, sodium, potassium, and calcium, allows for a higher (theoretical) energy density of aluminum-ion batteries (more energy per unit volume - 8100 Wh / kg). The volumetric capacity of aluminum (four to seven times that of lithium and sodium, respectively) offers the potential for a large increase in battery energy density.

[0011] Furthermore, aluminum-ion batteries are safer to operate than the other ion batteries described above; their electrolytes are not flammable, or are much less flammable than the electrolytes of LIBs; they have a reduced environmental impact compared to other ion batteries, as the main component of the battery - aluminum - can be easily recycled; they are simple to operate in the surrounding environment, which can offer safety benefits compared to other metal-ion batteries; they are cheaper to manufacture compared to other ion batteries; and use a more abundant base material.

[0012] Cathode materials for rechargeable aluminum-ion batteries have a number of inherent problems, including low discharge potential; unstable discharge voltage plateau, which means that the battery does not recognize a cutoff voltage; poor electrochemical reversibility such that the coulombic efficiency is low; limited cycle life and structural disintegration of the cathode such that the discharge capacity is low and unstable, decaying sharply after a few cycles.

[0013] Since cathode materials are specific to each battery type, a material that performs well in one battery type is unlikely to provide similar performance in an aluminum-ion battery. For example, a cathode for a lithium-ion battery would not be able to provide equal performance in an aluminum-ion battery. Furthermore, a material for an anode can not be able to function as a cathode due to the physical properties of the material required to function as an anode or cathode, respectively.

[0014] It is therefore an object of the present invention to provide a cathode for an aluminum-ion battery that overcomes the deficiencies of the prior art or at least provides the public with a useful choice.

[0015] Alternatively, it is an object of the present invention to provide an aluminum-ion battery comprising a cathode that overcomes some of the deficiencies of the prior art or at least provides the public with a useful choice. SUMMARY

[0017] Cathode

[0018] In one aspect of the present invention, there is provided a cathode material for an aluminum-ion battery, wherein the cathode material comprises a main group element nitride.

[0019] In another aspect of the present invention, there is provided a cathode material for an aluminum-ion battery, wherein the cathode material comprises a Group 13 element nitride.

[0020] In another aspect of the present invention, there is provided a cathode material for an aluminum-ion battery, wherein the cathode material comprises a boron nitride.

[0021] In another aspect of the present invention, there is provided a cathode material for an aluminum-ion battery, wherein the cathode material comprises a carbon nitride.

[0022] In another aspect of the present invention, there is provided a cathode material for an aluminum-ion battery, wherein the cathode material comprises a silicon nitride.

[0023] In another aspect of the present invention, there is provided a cathode material for an aluminum-ion battery, wherein the cathode material comprises an aluminum nitride.

[0024] In another aspect of the present invention, there is provided a cathode material for an aluminum-ion battery, wherein the cathode material comprises a lithium nitride.

[0025] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises an oxide of boron.

[0026] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, which comprises a main group element nitride and a main group element chalcogenide.

[0027] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, which comprises a main group element nitride and a group 1-13 element chalcogenide.

[0028] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a main group element nitride and a group 13 element chalcogenide.

[0029] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a main group element nitride and a boron chalcogenide.

[0030] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, which comprises a main group element nitride and a main group element oxide.

[0031] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, which comprises a main group element nitride and a group 1-13 element oxide.

[0032] In one example, the group 1-13 element oxide can be selected from an oxide of a transition metal element. Specific examples of transition metal oxides can include oxides of titanium and manganese.

[0033] In one example, the main group element nitride can be selected from a nitride of boron, carbon, aluminum, and silicon.

[0034] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a main group element nitride and a group 13 element oxide.

[0035] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a main group element nitride and an oxide of boron.

[0036] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a group 13 element nitride and a main group element chalcogenide.

[0037] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0038] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0039] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0040] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0041] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0042] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0043] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0044] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0045] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0046] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0047] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a Group 13 element and a chalcogenide of an element from Groups 1-13 of the Periodic Table.

[0048] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a main group element and an oxide of a Group 1-13 element.

[0049] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a main group element and an oxide of a Group 1-13 element.

[0050] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a main group element and an oxide of a Group 13 element.

[0051] In another aspect of the application, a cathode material for an aluminum-ion battery is provided, wherein the cathode material comprises a nitride of a main group element and an oxide of a Group 13 element.

[0052] In one example, the main group element nitride is selected from the group consisting of carbon nitride, lithium nitride, aluminum nitride, boron nitride, silicon nitride, gallium nitride, and indium nitride. Preferably, the main group element nitride is selected from the group consisting of carbon nitride, boron nitride, silicon nitride, and aluminum nitride.

[0053] In one example, the Group 1-13 element chalcogenide is selected from the group consisting of alkali metal chalcogenides, alkaline earth metal chalcogenides, transition metal (Groups 3-12) chalcogenides, and Group 13 element chalcogenides. The alkali metal chalcogenide can be selected from the group consisting of lithium, sodium, potassium, and rubidium chalcogenides. The alkaline earth metal chalcogenide can be selected from the group consisting of beryllium, magnesium, calcium, strontium, and barium chalcogenides. The transition metal chalcogenide can be selected from the group consisting of scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold, and mercury chalcogenides. Preferably, the transition metal chalcogenide is selected from the group consisting of titanium, manganese, vanadium, iron, nickel, zinc, molybdenum, and tantalum chalcogenides. The Group 13 chalcogenide can be selected from the group consisting of boron, aluminum, gallium, indium, and thallium chalcogenides.

[0054] In one example, the Group 1-13 element chalcogenide is selected from the group consisting of oxides of Group 1-13 elements, including oxides of transition metal elements. Specific examples of transition metal oxides include oxides of titanium and manganese.

[0055] In one example, the main group chalcogenide is selected from the group consisting of main group oxides. In one example, the main group chalcogenide is selected from the group consisting of boron chalcogenides. In one particular example, the main group chalcogenide is selected from the group consisting of boron oxides. In a more particular example, the boron oxide is boric anhydride (B2O3).

[0056] In one example, the main group nitride can comprise a morphology selected from 2D layered materials, crystalline materials, nanoparticles, quantum dots, nanowires, nanoplates, nanorods, microparticle plates, and flowers. Such morphologies are familiar to those skilled in the art. In one example, the morphology is a 2D layered material. In one example, the main group nitride is a 2D layered material of carbon nitride, silicon nitride, aluminum nitride, and boron nitride. In a particular example, the main group nitride is hexagonal boron nitride.

[0057] Alternatively, when the nitride is boron nitride, the boron nitride can be in any polymorph, including: cubic (sphalerite structure), wurtzite boron nitride, and hexagonal boron nitride.

[0058] In one example, when the cathode material comprises a main group element nitride and a chalcogenide of a Group 1-13 element, the weight ratio of the chalcogenide to the nitride in the cathode material can be between 5:95 to 95:5, between 10:90 to 90:10, between 20:80 to 80:20, between 30:70 to 70:30, between 40:60 to 60:40, or between 45:55 to 55:45. In a particular example, the ratio is approximately 50:50. In one example, the proportion of chalcogenide is at least 5 wt% of the active material in the cathode. In one example, the proportion of nitride is at least 5 wt% of the active material in the cathode.

[0059] In one example, when the cathode material comprises an oxide of a Group 1-13 element and a main group element nitride, the weight ratio of the oxide to the nitride in the cathode material can be between 5:95 to 95:5, between 10:90 to 90:10, between 20:80 to 80:20, between 30:70 to 70:30, between 40:60 to 60:40, or between 45:55 to 55:45. In a particular example, the ratio is approximately 50:50. In one example, the proportion of oxide is at least 5 wt% of the active material in the cathode. In one example, the proportion of nitride is at least 5 wt% of the active material in the cathode.

[0060] In one example, when the cathode material comprises an oxide of boron and boron nitride, the weight ratio of the oxide of boron to boron nitride in the cathode material can be between 5:95 to 95:5, between 10:90 to 90:10, between 20:80 to 80:20, between 30:70 to 70:30, between 40:60 to 60:40, or between 45:55 to 55:45. In one particular example, the ratio is approximately 50:50. In one example, the proportion of the oxide of boron is at least 5% by weight of the active material in the cathode.

[0061] In one example, the proportion of boron nitride is at least 5% by weight of the active material in the cathode.

[0062] In one example, the active material of the cathode consists essentially of a combination of a main group element nitride and a chalcogenide of a Group 1-13 element.

[0063] In one example, the cathode material comprises a nanostructure or a mesostructure to provide increased surface area and improved contact with the electrolyte. For example, nanostructures and mesostructures include nanopores and / or mesopores.

[0064] In one example, the main group nitride can be a particle size of 0.5 nm - 100 μιη.

[0065] In one example, the oxide can be a particle size of 0.5 nm - 100 μιη.

[0066] In one example, the cathode material comprises a binder. The binder can be a non- conductive material, such as a polymer. Those skilled in the art will readily appreciate that the binder serves to assist in the preparation of the cathode and to assist in the adhesion of the cathode to the current collector when assembled into a battery. Those skilled in the art will appreciate suitable binders for use on cathodes. Preferably, the binder is selected from the group consisting of polyvinylidene fluoride (PVDF) and polytetrafluoroethylene (PTFE).

[0067] In one example, the cathode for an aluminium-ion battery can comprise a conductive material. The conductive material can be selected from the group consisting of: conductive carbon, acetylene black, and mixtures thereof. Those skilled in the art will appreciate that the conductive carbon is intended to offset the reduction in electrical conductivity provided by the addition of the binder.

[0068] In one example, the cathode comprises at least 75% (by weight) active material, or more preferably at least 80% (by weight) active material, or more preferably approximately 85% (by weight) active material.

[0069] In one example, the active material of the cathode of the present application consists essentially of the oxides and / or nitrides specified herein. For example, in one embodiment of the cathode of the present application, the active material consists essentially of oxides of boron and nitrides of boron.

[0070] Battery

[0071] In another aspect of the present application, an aluminum-ion battery is provided, wherein the aluminum-ion battery comprises a cathode as described herein, such as a cathode comprising a main group element nitride.

[0072] Anode

[0073] In one example, the aluminum-ion battery further comprises an anode, such as an aluminum anode.

[0074] In one example, the anode can comprise at least one compound or material capable of functioning as an anode in a battery. For example, the anode can comprise a material suitable for use with the electrolyte and cathode of the aluminum-ion battery.

[0075] The aluminum anode can comprise at least one material that can undergo a process selected from the group consisting of: (i) intercalation; and (ii) reversible electrochemical deposition and dissolution at the expected operating temperature of the battery according to the present application.

[0076] One of skill in the art will readily appreciate materials suitable for use as an anode in the aluminum-ion battery described herein. However, for the avoidance of doubt, materials suitable for use in the anode include: aluminum foil, such as aluminum sheet, thin aluminum metal disc, aluminum alloy. In one example, the anode is an aluminum disc. In one example, the aluminum disc is approximately 0.1 mm in thickness and approximately 99% aluminum purity. Alternatively, suitable anodes include aluminum alloys comprising aluminum and at least one selected from the group consisting of: chromium, cobalt, copper, iron, lithium, magnesium, manganese, nickel, silicon, tin, titanium, tungsten, vanadium, zinc, and zirconium.

[0077] Electrolyte

[0078] In one example, the aluminum-ion battery comprises an electrolyte, wherein the electrolyte provides an electrical connection between the cathode and the anode and facilitates the movement of ions between them during the charging and discharging of the battery.

[0079] In one example, the electrolyte comprises at least one ion suitable for use in an aluminum-ion battery. Suitable electrolytes comprise ions of at least one selected from the group consisting of Al 3+ , Mg 2+ , Li + , Na + , K + , or combinations thereof.

[0080] In one example, the electrolyte is an ionic liquid. The ionic liquid can have properties and / or characteristics that make it suitable or suitable for use in an ionic battery. For example, the ionic liquid can be selected for use with a particular anode / cathode pair. Beneficial properties of the electrolyte include preventing or reducing anode oxidation; and / or preventing or reducing the generation of byproducts during the charging and discharging of the battery in use. Such byproducts include: chlorine gas; hydrogen gas when using aqueous electrolytes.

[0081] In other preferred embodiments, the ionic liquid can be any ionic liquid that can act as a Lewis acid. As will be readily appreciated by one skilled in the art, Lewis acid properties are beneficial because Lewis acids: (i) prevent or reduce the formation of an oxide layer (AI2O3) on the anode; (ii) prevent or reduce the formation of dendrites that can puncture the separator and cause a short circuit; (ii) prevent or reduce the release of chlorine gas that can be released when using aqueous electrolytes such as NaCI, KCI.

[0082] Suitable ionic liquids include those that can be safely used in an aluminum ionic battery and are familiar to one skilled in the art. Suitable ionic liquids can include: imidazolium ionic liquids including: ethylmethylimidazolium halides (such as chloride, bromide, iodide, and mixtures thereof); ionic liquids including: aqueous solutions of acetamides, ureas, NaCI-AICI3, aluminum salts, and metal hydroxides, and mixtures thereof. In one example, the ionic liquid includes: aluminum chloride and 1-ethylmethylimidazolium halide. In another example, the 1-ethylmethylimidazolium halide is selected from the group consisting of 1-ethylmethylimidazolium chloride, 1-ethylmethylimidazolium bromide, 1-ethylmethylimidazolium iodide, and mixtures thereof.

[0083] In one particular example, the ionic liquid can include a combination of aluminum chloride (AICI3) and 1-ethyl-3-methylimidazolium chloride ([EMIm]CI). More particularly, the ionic liquid can be aluminum chloride (AICI3) and 1-ethyl-3-methylimidazolium chloride at a ratio of about 1 : 1 to about 1.5: 1, such as about 1.3: 1.

[0084] Other electrolytes are contemplated as suitable for use in the present application, including those that include different ions and in different concentration ranges.

[0085] Separator

[0086] In further embodiments, the aluminum ionic battery includes an ion-permeable separator for separating the cathode and anode in the aluminum ionic battery.

[0087] Suitable separators are known to those skilled in the art and can be selected from the group consisting of: polymers including: PTFE (polytetrafluoroethylene), cellulose acetate, nitrocellulose, polysulfone, polyethersulfone, polyacrylonitrile, polyamide, polyimide, polyethylene, polyvinyl chloride (PVC); NAFION, nylon, ceramic, polyester, rubber; glass separators including: glass microfibres; glass mats; and mixtures and combinations thereof.

[0088] In one example, the separator is a web made of a non-conductive material. In one example, the separator is a glass microfiber. In another example, the separator is an ion- permeable membrane.

[0089] Current collector

[0090] In further embodiments, the aluminium-ion battery can comprise one or more current collectors. In one example, a current collector is present on both the anode and cathode side of the battery. The battery can include a current collector for the cathode and / or anode. The current collector can be a substrate to which the cathode is attached and which, in use, facilitates the flow of electrons through an external circuit during discharge (and charge, as appropriate) of the battery. Examples of suitable current collectors include any material or combination of materials that can conduct electricity. The current collector can be a web / sheet / foil made of any metal that does not react with the electrolyte. Preferably, the current collector is selected from the group consisting of: molybdenum, nickel and tungsten.

[0091] Battery

[0092] In a further aspect of the application, there is provided an aluminium-ion battery cell comprising a cathode as described herein.

[0093] In one example, the battery further comprises an aluminium-containing anode.

[0094] In one example, the battery further comprises an electrolyte.

[0095] In one example, the battery further comprises an ion-permeable separator.

[0096] In a further aspect of the application, there is provided an aluminium-ion battery cell comprising a cathode, wherein the cathode comprises an oxide of boron and boron nitride, wherein the ratio of the oxide of boron to boron nitride is between 5:95 to 95:5 (by weight).

[0097] Battery module

[0098] In a further aspect of the application, there is provided an aluminium-ion battery module comprising two or more aluminium-ion battery cells, wherein at least one aluminium-ion battery cell comprises a cathode as described herein.

[0099] Electrical device

[0100] In a further aspect of the application, an electrical device is provided, wherein the electrical device comprises an aluminum-ion battery substantially as described herein.

[0101] Use

[0102] In a further aspect of the application, use of a cathode as described herein in an aluminum-ion battery is provided.

[0103] In a further aspect of the application, use of a main group element nitride in the manufacture of a cathode of an aluminum-ion battery cell is provided.

[0104] In a further aspect of the application, use of a main group element chalcogenide in the manufacture of a cathode of an aluminum-ion battery cell is provided.

[0105] In a further aspect of the application, use of a combination of a main group element nitride and a chalcogenide of a group 1-13 element in the manufacture of a cathode of an aluminum-ion battery cell is provided.

[0106] In a further aspect of the application, use of a combination of an oxide of boron and boron nitride in the manufacture of a cathode of an aluminum-ion battery cell is provided, wherein the ratio of the oxide of boron to boron nitride is between 5:95 and 95:5 (by weight).

[0107] According to a further embodiment of the application, the aluminum-ion battery can be used in an electrical device: an electric bicycle; an electric car; a computer; a handheld electrical device, a phone, a tablet; a grid storage device.

[0108] Manufacturing method

[0109] In a further aspect of the application, a method of manufacturing a battery is provided, wherein the method comprises the step of forming a cathode comprising a main group element nitride or a chalcogenide of a group 1-13 element or a combination thereof in the manufacture of a cathode for an aluminum-ion battery cell.

[0110] In a further aspect of the application, a method of manufacturing a cathode for an aluminum-ion battery is provided, wherein the method comprises the step of forming a cathode using a main group element nitride or a chalcogenide of a group 1-13 element or a combination thereof.

[0111] In a further embodiment of the application, the method of manufacturing a cathode for an aluminum-ion battery comprises the steps of:

[0112] (i) preparing a slurry, wherein the slurry comprises mixing, not in a specific order:

[0113] a. a main group element nitride and / or a chalcogenide of a group 1-13 element;

[0114] b. a polar solvent;

[0115] c. optionally, a binder;

[0116] d. optionally, a conductive material;

[0117] (ii) applying the slurry to a collector material;

[0118] (iii) drying the slurry to provide a dried product.

[0119] The dried product preferably comprises at least 75% (by weight) of active material, or more preferably at least 80% (by weight) of active material, or more preferably about 85% (by weight) of active material.

[0120] The polar solvent can be selected from the group consisting of water, ethanol, methanol, dimethylsulfoxide (DMSO), dimethylformamide (DMF) and N-methyl- pyrrolidone (NMP). In a preferred embodiment, the solvent is N-methyl-2-pyrrolidone (NMP).

[0121] The above discussion should not be taken as limiting the scope of the application. Other electrolytes are contemplated as being suitable for use in the present application, including those comprising different ions and in different concentration ranges.

[0122] It should also be understood that a battery according to the present application can include other components necessary to ensure the desired performance. Representative additional components that can be included in a battery are described herein in a manner that should be understood as non-limiting.

[0123] Further embodiments of the present application that should be considered in all novel embodiments of the present application will be apparent to those skilled in the art upon reading the following description, which provides at least one example of a practical application of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0125] One or more embodiments of the present application are described below by way of example only, and are not intended to be limiting, with reference to the following drawings, in which:

[0126] Figure 1 is a representative schematic of an aluminum-ion battery according to one embodiment of the present application comprising an AICI3 / imidazolium chloride ionic liquid electrolyte, showing the flow of electrons during the charging and discharging cycles of the battery.

[0127] Figure 2 shows a schematic of a laboratory prototype. It shows the electrode arrangement within the battery.

[0128] Figure 3Aluminum-ion batteries showing the charge / discharge curves of cathodes containing B2O3 and hexagonal boron nitride in a 1 : 1 ratio (by weight) at 50 mA / g (□), 500 mA / g (O), 900 mA / g (Δ), 1000 mA / g (◇), 1500 mA / g (☆), and at 50 mA / g

[0129] Figure 4 Aluminum-ion batteries showing the charge / discharge curves of cathodes containing B2O3 and hexagonal boron nitride in a 1 : 1 ratio (by weight) at 50 mA / g (□), 500 mA / g (O), 900 mA / g (Δ), 1000 mA / g (◇), 1500 mA / g (☆), and at 50 mA / g of current density at the 50th (A), 20th (B), 10th (C), 2nd (D), and 1st (E) cycles.

[0130] Figure 5 Aluminum-ion batteries showing the plots of specific capacity and coulombic efficiency of cathodes containing B2O3 and hexagonal boron nitride in a 1 : 1 ratio (by weight) over repeated charge / discharge cycles, switching from 50 mA / g (A) to 500 mA / g (B) to 900 mA / g (C) to 1 A / g (D) to 1.5 A / g (E) and back to 50 mA / g (A) at intervals of about 20 cycles. The symbol ■ indicates the specific capacity and the symbol O represents the coulombic efficiency.

[0131] Figure 6 Aluminum-ion batteries showing the charge / discharge curves of cathodes containing B2O3 and carbon nitride (C3N4) in a 1 : 1 ratio (by weight) at 50 mA / g (□), 500 mA / g (Δ), 900 mA / g (▽), 1000 mA / g (◇), 1500 mA / g (☆), at 50 mA / g of current density at the 50th (A), 20th (B), 10th (C), 2nd (D), and 1st (E) cycles.

[0132] Figure 7 Aluminum-ion batteries showing the plots of specific capacity and coulombic efficiency of cathodes containing B2O3 and carbon nitride (C3N4) in a 1 : 1 ratio (by weight) over repeated charge / discharge cycles, switching from 50 mA / g (A) to 500 mA / g (B) to 900 mA / g (C) to 1 A / g (D) to 1.5 A / g (E) and back to 50 mA / g (A) at intervals of about 20 cycles. The symbol ■ indicates the specific capacity and the symbol O represents the coulombic efficiency.

[0133] Figure 8Charge / Discharge curves of an aluminum-ion battery showing a cathode comprising aluminum nitride (AIN) with a 1 : 1 ratio (by weight) of B2O3 and AIN at a current density of 50 mA / g (□), 500 mA / g (O), 1000 mA / g (A), 1500 mA / g (0), and 50 mA / g (T) at the 100th cycle.

[0134] Figure 9 Graph of specific capacity and coulombic efficiency of an aluminum-ion battery showing a cathode comprising aluminum nitride (AIN) with a 1 : 1 ratio (by weight) of B2O3 and AIN over repeated charge / discharge cycles, converting from 50 mA / g (A) to 500 mA / g (B) to 1 A / g (C) to 1.5 A / g (D) and back to 50 mA / g (A) at intervals of about 20 cycles. Symbol■indicates specific capacity and symbol O represents coulombic efficiency.

[0135] Figure 10 Charge / Discharge curves of an aluminum-ion battery showing a cathode comprising silicon nitride (Si3N4) with a 1 : 1 ratio (by weight) of B2O3 and Si3N4 at a current density of 50 mA / g (□), 500 mA / g (A), 1000 mA / g (0), 1500 mA / g and 50 mA / g (T) at the 100th cycle.

[0136] Figure 11 Graph of specific capacity and coulombic efficiency of an aluminum-ion battery showing a cathode comprising silicon nitride (Si3N4) with a 1 : 1 ratio (by weight) of B2O3 and Si3N4 over repeated charge / discharge cycles, converting from 50 mA / g (A) to 500 mA / g (B) to 1 A / g (C) to 1.5 A / g (D) and back to 50 mA / g (A) at intervals of about 20 cycles. Symbol■indicates specific capacity and symbol O represents coulombic efficiency.

[0137] Figure 12 Charge / Discharge curves of an aluminum-ion battery showing a cathode comprising boron nitride (h-BN) with a 1 : 1 ratio (by weight) of MnO2 and h-BN at a current density of 50 mA / g (□), 500 mA / g (O), 1000 mA / g (A), 1500 mA / g and 50 mA / g (T) at the 100th cycle.

[0138] Figure 13Graph showing the specific capacity and coulombic efficiency of an aluminum-ion battery comprising a cathode with Mn02and hexagonal boron nitride in a 1 : 1 ratio (by weight) over repeated charge / discharge cycles, switching from 50 mA / g (A) to 500 mA / g (B) to 1 A / g (C) to 1.5 A / g (D) and back to 50 mA / g (A) at intervals of about 20 cycles. The symbol■indicates specific capacity and the symbol o represents coulombic efficiency.

[0139] Figure 14 Graph showing the charge / discharge curves at current densities of 50 mA / g (□), 500 mA / g (o), 1000 mA / g (0), 1500 mA / g and 50 mA / g (T) at the 20th cycle and 50 mA / g (o) at the 100th cycle for an aluminum-ion battery comprising a cathode with Mn02and carbon nitride in a 1 : 1 ratio (by weight).

[0140] Figure 15 Graph showing the specific capacity and coulombic efficiency of an aluminum-ion battery comprising a cathode with Mn02and carbon nitride in a 1 : 1 ratio (by weight) over repeated charge / discharge cycles, switching from 50 mA / g (A) to 500 mA / g (B) to 1 A / g (C) to 1.5 A / g (D) and back to 50 mA / g (A) at intervals of about 20 cycles. The symbol■indicates specific capacity and the symbol o represents coulombic efficiency.

[0141] Figure 16 Graph showing the charge / discharge curves at current densities of 50 mA / g (□), 500 mA / g (A), 1000 mA / g (0), 1500 mA / g and 50 mA / g (o) at the 20th cycle and 50 mA / g (T) at the 100th cycle for an aluminum-ion battery comprising a cathode with Mn02and silicon nitride in a 1 : 1 ratio (by weight).

[0142] Figure 17 Graph showing the specific capacity and coulombic efficiency of an aluminum-ion battery comprising a cathode with Mn02and silicon nitride in a 1 : 1 ratio (by weight) over repeated charge / discharge cycles, switching from 50 mA / g (A) to 500 mA / g (B) to 1 A / g (C) to 1.5 A / g (D) and back to 50 mA / g (A) at intervals of about 20 cycles. The symbol■indicates specific capacity and the symbol o represents coulombic efficiency.

[0143] Figure 18Charge / Discharge curves of an aluminum-ion battery showing a cathode comprising Ti02and hexagonal boron nitride in a 1 : 1 ratio (by weight) at a current density of 50 mA / g (□), 500 mA / g (O), 1000 mA / g (A), 1500 mA / g (0), and 50 mA / g (T) at the 100th cycle.

[0144] Figure 19 Graph showing the specific capacity and coulombic efficiency of an aluminum-ion battery showing a cathode comprising Ti02and hexagonal boron nitride in a 1 : 1 ratio (by weight) over repeated charge / discharge cycles, switching from 50 mA / g (A) to 500 mA / g (B) to 1 A / g (C) to 1.5 A / g (D) and back to 50 mA / g (A) at intervals of about 20 cycles. The symbol■indicates specific capacity and the symbol O represents coulombic efficiency.

[0145] Figure 20 Charge / Discharge curves of an aluminum-ion battery showing a cathode comprising Ti02and carbon nitride in a 1 : 1 ratio (by weight) at a current density of 50 mA / g (□), 500 mA / g (A), 1000 mA / g (0), 1500 mA / g and 50 mA / g (O) at the 20th cycle and 50 mA / g (T) at the 100th cycle.

[0146] Figure 21 Graph showing the specific capacity and coulombic efficiency of an aluminum-ion battery showing a cathode comprising Ti02and carbon nitride in a 1 : 1 ratio (by weight) over repeated charge / discharge cycles, switching from 50 mA / g (A) to 500 mA / g (B) to 1 A / g (C) to 1.5 A / g (D) and back to 50 mA / g (A) at intervals of about 20 cycles. The symbol■indicates specific capacity and the symbol O represents coulombic efficiency.

[0147] Figure 22 Charge / Discharge curves of an aluminum-ion battery showing a cathode comprising active material consisting of B203and hexagonal boron nitride in a B203:hBN ratio of 75:25 (T), 80:20 85:15 (0), 90:10 (O), 95:5 (by weight) and 100% B203(□).

[0148] Figure 23 a) in the figure shows the charge / discharge cycles of an aluminum-ion battery comprising B203as active material at a current rate of 50 mA / g at the first cycle (□), the second cycle (O), and the 15th cycle (T). Figure 23Figure 6 shows the charge / discharge curves of an aluminum-ion battery comprising a cathode with B2O3 / hBN active material in a 1 : 1 ratio (by weight) at a current rate of 50 mA / g at the first cycle (□), second cycle (O), 10th cycle (A), and 20th cycle (T).

[0149] Figure 24 Figure 7 shows the charge / discharge curves of an aluminum-ion battery comprising a cathode with a boron anhydride:hexagonal boron nitride ratio of 5:95 (by weight) at a current density of 50 mA / g (□) and 1000 mA / g (O) and 50 mA / g (T) at the 100th cycle.

[0150] Figure 25 Figure 8 shows the plot of specific capacity and coulombic efficiency of an aluminum-ion battery comprising a cathode with a boron anhydride:hexagonal boron nitride ratio of 5:95 (by weight) over repeated charge / discharge cycles, switching from 50 mA / g (A) to 500 mA / g (B) to 1 A / g (C) to 1.5 A / g (D) and back to 50 mA / g (A) at approximately 20 cycle intervals.

[0151] Figure 26 Figure 9 shows the charge / discharge curves of an aluminum-ion battery comprising a cathode with hexagonal boron nitride (100% of the active material) at a current density of 50 mA / g (T□A◇) and 500 mA / g (O) at the first few cycles.

[0152] Figure 27 Figure 10 shows the plot of specific capacity and coulombic efficiency of an aluminum-ion battery comprising a cathode with hexagonal boron nitride (100% of the active material) over repeated charge / discharge cycles, where the first approximately 25 cycles are at 50 mA / g (A) and switch to 500 mA / g for approximately 25 cycles (B). The symbol■indicates the specific capacity and the symbol O represents the coulombic efficiency.

[0153] Definitions

[0154] "Main group elements" means the elements of Groups 1 and 2 (s-block) and Groups 13-17 (p-block, excluding noble gases) of the Periodic Table.

[0155] "Group 13 elements" means boron, aluminum, gallium, indium, and tellurium.

[0156] "Sulfide" means a compound of sulfur with a metal.

[0157] With respect to cathode materials in a battery, "active material" means the material in the cathode that undergoes a reaction during discharge of the battery to partially generate the electromotive force.

[0158] Detailed Description

[0159] Aluminum-ion batteries are a promising alternative to other ion batteries such as lithium-ion batteries. The present invention relates to cathodes for aluminum-ion batteries. Ion batteries work with a reversible electrochemical deposition and dissolution process. During discharge of an ion battery, ions can be inserted into the interstices between layers of material forming the cathode, and electrons flow from the anode to the cathode to provide an EMF (electromotive force) to drive a load. During charging of the battery, this process is reversed, i.e. ions are removed from the interstices between layers of material forming the cathode, and electrons flow from the cathode to the anode.

[0160] The present inventors have surprisingly found that nitride compounds of main group elements exhibit surprisingly good activity as cathode active materials for aluminum-ion batteries.

[0161] The present inventors have surprisingly found that boron oxide compounds, in particular boron anhydride, exhibit surprisingly good activity as cathode active materials for aluminum-ion batteries.

[0162] The present inventors have further surprisingly found that a combination of nitride compounds of main group elements and oxides of Groups 1-13 exhibit surprisingly good activity as cathode active materials for aluminum-ion batteries.

[0163] In particular, the present inventors have surprisingly found that a combination of boron nitride and boron oxide exhibit surprisingly good activity as cathode active materials for aluminum-ion batteries. Furthermore, the present inventors have surprisingly found that a combination of hexagonal boron nitride and boron anhydride exhibit surprisingly good activity as cathodes for aluminum-ion batteries.

[0164] Reference is made to Figure 1 and 2 which are representative schematic illustrations of a battery (100) according to an embodiment of the present invention. The battery (100) is an aluminum-ion battery having a cathode (102) and an anode (104) provided within a housing (106). The housing (106) can be any housing suitable for a battery and readily understood by one skilled in the art. For example, suitable housings can include, but are not limited to: coin cells, pouch cells, cylindrical cells, prismatic cells. An electrolyte (108) in the form of an ionic liquid is provided in the housing (106) which provides an electrical connection between the cathode (102) and the anode (104) when the battery (100) is charged or discharged.

[0165] The battery (100) also includes a separator (110) structured and / or arranged to prevent direct contact of the anode and cathode with each other. The separator (110) is preferably glass microfiber installed in the housing (106). However, one skilled in the art will recognize any material or structure that is electrically insulating and can prevent contact of the cathode and anode.

[0166] The cathode (102) and anode (104) each have terminals (120) and (120'), respectively. The terminals (120 and 120') are rods, such as molybdenum rods, that facilitate connection of the battery to an external load or charging device. Figure 2

[0167] Further embodiments of the battery (100) will become more apparent from the following description of its particular components.

[0168] Referring to Figures 3 to 5 and Figure 23 , an aluminum-ion battery cell was prepared according to the method described in the examples, comprising a cathode having an active material consisting of a 1 : 1 ratio of boron anhydride and hexagonal boron nitride (Cell 4 in Table 1). The cell cycled at 50 mA / g exhibited specific capacities near 220 mAh / g at a current density of 50 mA / g and stabilized between about 10-25 mAh / g at a current density of 500-1500 mA / g.

[0169] Referring to Figure 6 and 7 , an aluminum-ion battery cell was prepared according to the method described in the examples, comprising a cathode having an active material consisting of a 1 : 1 ratio of boron anhydride and carbon nitride C3N4 (Cell 10 in Table 1). The cell cycled at 50 mA / g exhibited a coulombic efficiency that stabilized at about 100% and specific capacities near 90-120 mAh / g at a current density of 50 mA / g and stabilized between about 10-30 mAh / g at a current density of 500-1500 mA / g.

[0170] Referring to Figure 8 and 9 , an aluminum-ion battery cell was prepared according to the method described in the examples, comprising a cathode having an active material consisting of a 1 : 1 ratio of boron anhydride and aluminum nitride AlN (Cell 11 in Table 1). The cell cycled at 50 mA / g exhibited specific capacities near 32-34 mAh / g at a current density of 50 mA / g and stabilized at about 15-20 mAh / g at a current density of 500-1500 mA / g.

[0171] Referring to Figure 10 and 11 ​Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of boron anhydride and silicon nitride, Si3N4(Table 1, Cell 12). The cells cycled at 50 mA / g exhibited coulombic efficiencies stable at about 100% and specific capacities around 25-28 mAh / g at a current density of 50 mA / g and stable at about 10-20 mAh / g at a current density of 500-1500 mA / g.

[0172] Referring to Figure 12 and 13 Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of manganese oxide (Mn02) and hexagonal boron nitride (Table 1, Cell 13). The cells cycled at 50 mA / g exhibited coulombic efficiencies stable at about 100% and specific capacities around 27-29 mAh / g at a current density of 50 mA / g and stable at about 10-20 mAh / g at a current density of 500-1500 mA / g.

[0173] Referring to Figure 14 and 15 Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of manganese oxide (Mn02) and carbon nitride, C3N4(Table 1, Cell 14). The cells cycled at 50 mA / g exhibited coulombic efficiencies stable at about 100% and specific capacities around 30 mAh / g at a current density of 50 mA / g and stable at about 10-20 mAh / g at a current density of 500-1500 mA / g.

[0174] Referring to Figure 16 and 17 Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of manganese oxide (Mn02) and silicon nitride, Si3N4(Table 1, Cell 15). The cells cycled at 50 mA / g exhibited coulombic efficiencies stable at about 100% and specific capacities around 40-55 mAh / g at a current density of 50 mA / g and stable at about 10-20 mAh / g at a current density of 500-1500 mA / g.

[0175] Referring to Figure 18 and 19Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of titanium oxide (Ti02) and hexagonal boron nitride (Table 1, Cell 16). The cells cycled at 50 mA / g exhibited coulombic efficiencies stabilized at approximately 100% and specific capacities around 60 mAh / g at a current density of 50 mA / g and stabilized at approximately 20-30 mAh / g at current densities of 500-1500 mA / g.

[0176] Referring to Figure 20 and 21 Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of titanium oxide (Ti02) and hexagonal boron nitride (Table 1, Cell 16). The cells cycled at 50 mA / g exhibited coulombic efficiencies stabilized at approximately 100% and specific capacities around 60 mAh / g at a current density of 50 mA / g and stabilized at approximately 20-30 mAh / g at current densities of 500-1500 mA / g.

[0177] Referring to Figure 22 Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of titanium oxide (Ti02) and hexagonal boron nitride (Table 1, Cell 16). The cells cycled at 50 mA / g exhibited coulombic efficiencies stabilized at approximately 100% and specific capacities around 60 mAh / g at a current density of 50 mA / g and stabilized at approximately 20-30 mAh / g at current densities of 500-1500 mA / g.

[0178] Referring to Figure 23 Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of titanium oxide (Ti02) and hexagonal boron nitride (Table 1, Cell 16). The cells cycled at 50 mA / g exhibited coulombic efficiencies stabilized at approximately 100% and specific capacities around 60 mAh / g at a current density of 50 mA / g and stabilized at approximately 20-30 mAh / g at current densities of 500-1500 mA / g.

[0179] Referring to Figure 24 and 25 Aluminum-ion battery cells were prepared according to the methods described in the examples, comprising cathodes with active materials consisting of a 1 : 1 ratio of titanium oxide (Ti02) and hexagonal boron nitride (Table 1, Cell 16). The cells cycled at 50 mA / g exhibited coulombic efficiencies stabilized at approximately 100% and specific capacities around 60 mAh / g at a current density of 50 mA / g and stabilized at approximately 20-30 mAh / g at current densities of 500-1500 mA / g.

[0180] Referring to Figure 26 and27 An aluminum-ion battery cell was prepared according to the method described in the examples comprising a cathode with active material consisting of 100% hexagonal boron nitride (Table 1, Cell 2). The cell cycled at 50 mA / g and 500 mA / g exhibited a coulombic efficiency that stabilized at about 90-100% and a specific capacity that stabilized at around 20 mAh / g at a current density of 50 mA / g and about 5-10 mAh / g at a current density of 500 mA / g.

[0181] Example 1 - Cathode fabrication

[0182] Generally, a slurry comprising 85% w / w active material was prepared by combining and mixing with 6% binder and 9% conductive material in a solvent at room temperature. The slurry was sonicated and continuously stirred to form a homogeneous mixture which was blade coated onto a current collector. The slurry was dried at room temperature and then dried under vacuum at 120 °C for 12 hours to evaporate any residual solvent. Discs were cut from the dried sheet and used as cathodes in laboratory battery test cells.

[0183] Example 2 - Fabrication of hexagonal boron nitride / boron oxide cathode materials

[0184] A 1 : 1 hexagonal boron nitride (hBN) / boron oxide cathode was prepared as follows: a slurry comprising a 1 : 1 mixture by weight (85 wt%) of boron oxide and boron nitride, polyvinyl diethylene fluoride (PVDF) binder (9 wt%) and conductive carbon (6 wt%) in N-methyl pyrrolidone was prepared. The slurry was blade coated onto a molybdenum foil (thickness 0.1 mm, MTI Corporation) and dried in a vacuum oven at 120 °C for 12 hours to adhere the slurry to the conductive substrate and evaporate the solvent. The specific loading of the hBN and boron oxide active materials was approximately 12 mg cm -2 .

[0185] hBN / boron oxide cathodes with 5%, 75%, 80%, 85%, 90%, 95% and 100% boron oxide were prepared following the procedure described above.

[0186] Example 3 - Fabrication of cathode materials comprising other oxide / nitride combinations

[0187] Cathode materials comprising combinations of oxides and nitrides listed in Table 1 were prepared following the methods described in Examples 1 and 2.

[0188] Example 4 - Electrolyte

[0189] The electrolyte was prepared by mixing anhydrous aluminium trichloride, AICI3 (Sigma-Aldrich) and 1-ethyl-3-methylimidazolium chloride, EMImCl (97%, Sigma-Aldrich) in a 1.3:1 molar ratio under inert conditions at room temperature.

[0190] Example 5 - Batteries

[0191] Polyether ether ketone (PEEK) pouch cells were prepared by placing a cathode at the bottom of a PEEK cell under inert conditions. A glass microfibre (grade GF / F, Whatman) separator was placed in the cell. 80 microlitres of the electrolyte of Example 4 was added to wet the separator. Aluminium foil (thickness 0.1 mm, 99%, GoodFellow) was used as anode and placed on top of the separator. The cell was then sealed to avoid air or moisture ingress into the cell.

[0192] Batteries were prepared using cathodes with the active materials (oxide component, nitride component) specified in Table 1, where each cathode was prepared according to the general procedure described in Example 2. The batteries were tested using a battery tester BTS 3000. Test parameters included a current density of 50, 500, 1000 or 1500 mA / g between a voltage of 0.02 and 2.35 V. Each battery was cycled 50 times at each current density. Batteries were prepared using cathodes with the active materials (oxide component, nitride component) specified in Table 1, where each cathode was prepared according to the general procedure described in Example 2. The batteries were tested using a battery tester BTS 3000. Test parameters included a current density of 50, 500, 1000 or 1500 mA / g between a voltage of 0.02 and 2.35 V. Each battery was cycled 50 times at each current density.

[0193]

[0194]

[0195] Table 1

[0196] ***

[0197] Unless the context clearly dictates otherwise, throughout the specification and claims, the word "comprise", and variations thereof (such as "comprises" and "comprising"), will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

[0198] Reference to numerical ranges disclosed herein (for example 1 to 10) is also intended to include reference to all rational numbers within that range (for example 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and any rational range of numbers within that range (for example 2 to 8, 1.5 to 5.5 and 3.1 to 4.7) and therefore all sub-ranges of all ranges expressly disclosed herein are hereby expressly incorporated by reference. These are merely examples of what is specifically intended and all possible combinations of between the lowest and highest value enumerated should be considered to be explicitly stated in the application in a similar manner.

[0199] The entire disclosure of all applications, patents and publications, cited above and below, are hereby incorporated by reference.

[0200] The mention of any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that this prior art forms part of the common general knowledge in the field of the technology concerned.

[0201] The present application may also be said broadly to include the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features.

[0202] Where an integer or integers or components having known equivalents thereof are referred to in the foregoing description as limiting the scope of the application, these integers or components are incorporated as limiting in this claim by virtue of having been recited as limiting in the description.

[0203] It should be noted that various alterations and modifications of the current preferred embodiments described herein will become apparent to others skilled in the art upon reading the foregoing description. It is intended that the application be construed as including all such alterations and modifications as fall within the scope of the application. Accordingly, the application is not limited to that precisely as shown and described.

[0204] References

[0205] Lin, Meng-Chang; Gong, Ming; Lu, Bingan; Wu, Yingpeng; Wang, Di-Yan; Guan, Mingyun; Angell, Michael; Chen, Changxin; Yang, Jiang; Hwang, Bing-Joe; Dai, Hongjie (6 April 2015). "An ultrafast rechargeable aluminium-ion battery". Nature. 520: 324–328. doi:10.1038 / nature14340. PMID 25849777.

[0206] Das, Shyamal K.; Mahapatra, Sadhan; Lahan, Homen (2017). "Aluminum-ion batteries: developments and challenges". Journal of Materials Chemistry A: 6347–6367. doi:10.1039 / c7ta00228a.

[0207] Ambroz, F.; Macdonald, T. J.; Nann, T. Trends in Aluminium-Based Intercalation Batteries. Adv. Energy Mater. 2017, 1602093.

[0208] Zafar, Z. A. et al. A super-long life rechargeable aluminum battery. Solid State Ion. 320, 70-75 (2018).

[0209] Eftekhari, A. Low voltage anode materials for lithium-ion batteries. Energy Storage Mater. 7, 157-180 (2017).

[0210] Mukherjee, R. & Koratkar, N. A. U.S. Patent No. 9,819,220.

[0211] Brown, G. M. et al. U.S. Patent No. 9,997,802.

Claims

1. A rechargeable aluminum-ion battery pack comprising a cathode, an aluminum anode, and an ion-conducting electrolyte, wherein the cathode comprises an active material comprising a boron oxide. Boron oxides comprise at least 75% (by weight) of the active material.

2. The aluminum-ion battery pack of claim 1, wherein the active material further comprises boron nitride.

3. The aluminum-ion battery pack of claim 2, wherein the ratio of boron oxide to boron nitride is between 5:95 and 95:5 (by weight).

4. The aluminum-ion battery pack of claim 2, wherein the ratio of boron oxide to boron nitride is between 10:90 and 90:10, or between 20:80 and 80:20, or between 30:70 and 70:30, or between 40:60 and 60:40 (by weight).

5. The aluminum-ion battery pack of claim 1, wherein the boron oxide comprises boron anhydride.

6. The aluminum-ion battery pack of claim 2, wherein boron nitride comprises a 2D layered material.

7. The aluminum-ion battery pack of claim 2, wherein the boron nitride comprises hexagonal boron nitride.

8. The aluminum-ion battery pack of claim 1, further comprising a conductive material.

9. The aluminum-ion battery pack of claim 8, wherein the conductive material comprises conductive carbon.

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